Running Gear, Axles, Steering AMAROK

Service
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Workshop Manual
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Running gear, axles, steering
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Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
40 - Front suspension
42 - Rear suspension
44 - Wheels, tyres, vehicle geometry
48 - Steering
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright 2013 Volkswagen AG, Wolfsburg D4B80275F7F

Amarok 2011
Running gear, axles, steering - Edition 01.2013
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Evaluating accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Checklist for evaluating running gear on accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . 1
2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Tyre types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.3 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.5 Raising wheel suspension to unladen position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
40 - Front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1 Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Overview - front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1 Assembly overview - subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3 Renewing anti-roll bar bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4 Removing and installing coupling rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3 Wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.1 Assembly overview - wheel bearing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3.3 Removing and installing wheel sw agen
bearing . . . . . . . . . . o.e.s n. o.t . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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4 Suspension strut, upper db
ise suspension link . . . . . . . . . . . . . . . .an.te. . . . . . . . . . . . . . . . . . . . . 24
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4.1 Assembly overview au - suspension strut, upper suspension link . . . r.ac. . . . . . . . . . . . . . . . . .
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4.2 Assembly overview s - suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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4.3 Removing and installing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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4.4 Removing and installing upper links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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4.5 Renewing bushes for upper suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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4.6 Repairing front suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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4.7 Removing and installing suspension strut mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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5 Lower suspension link, swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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5.1 Removing and installing lower suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

5.2 Renewing bonded rubber bush for lower suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.3 Checking swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
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6 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
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6.1 Assembly overview - drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

6.2 Removing and installing drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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6.3 Dismantling and assembling drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

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6.4 Checking outer constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

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42 - Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
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1 Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
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1.1 Overview - rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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1.2 Assembly overview - rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
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1.3 Assembly overview - rear axle shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
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1.4 Removing and installing bump stop for leaf spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
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1.5 Removing and installing rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.6 Removing and installing leaf spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1.7 Renewing rubber bush for leaf spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1.8 Removing and installing plastic insert for leaf spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
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Amarok 2011
1.9 Removing and installing rear axle shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

2 Suspension strut, shock absorber, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.1 Removing and installing shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
44 - Wheels, tyres, vehicle geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

1 Wheels, tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.1 Torque settings for wheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.2 Pressing tyre off wheel rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.3 Removing tyre from wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.4 Fitting tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.5 Wheel change, protecting wheel centring seat against corrosion . . . . . . . . . . . . . . . . . . . . 73
1.6 Wheel change, installation requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.7 Wheel change, installation instructions for wheel change . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.8 Wheel change, wheel installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2 Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.1 Notes for wheel alignmentG. V. o.lk.s.w.ag. e.n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
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2.2 Necessity of wheel agen
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2.3 Test prerequisitesdb . . . . . . . . . . . . . . . . . . . . . . u.a.ra.n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
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2.4 Test preparations
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ss values for wheel alignment . . . . . . . . . . . . . . c. . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
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2.6 Wheel alignment procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

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2.7 Measuring vehicle longitudinal inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

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Adjusting camber and caster at front wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
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2.9 Adjusting front axle toe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
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2.10 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

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2.11 Steering angle sender - basic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

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3 Vibration due to wheels/tyres - causes and rectification . . . . . . . . . . . . . . . . . . . . . . . . . . 86

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3.1 Causes of vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

3.2 Conducting a road test before balancing wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
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3.3 Balancing wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

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3.4 Vibration control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

3.5 Checking radial and lateral runout of wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3.6 Checking radial and lateral run-out on wheel rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
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3.7 Matching wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

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3.8 Determining flat spots on tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

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48 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
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1 Steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
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1.1 Assembly overview - steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

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1.2 Removing and installing steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
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2 Steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
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2.1 Assembly overview - steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
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2.2 Removing and installing steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.3 Handling and transporting steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.4 Checking steering column for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3 Steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.1 Assembly overview - steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.2 Removing and installing steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.3 Repairing steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3.4 Checking shock absorber mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3.5 Removing and installing shock absorber mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3.6 Removing and installing track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.7 Removing and installing track rod ball joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.8 Removing and installing boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4 Hydraulic power steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
ii Contents
Amarok 2011
Running
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4.1 Assembly overview - vane pump rise . . . . . . . . . . . . . . . . . . . . . . . . . . . . a.nt.e . . . . . . . . . .
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4.2 Assembly overview - hydraulic
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4.3 s of vane pump . . . . . . . . . . . . . . . . . . . . . . . . . . c. . . . . . . .
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Checking delivery pressure .... 121
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4.4 Removing and installing vane pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
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4.5 Checking power steering fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
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4.6 Bleeding steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
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4.7 Check steering for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
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Contents iii
Amarok 2011
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iv Contents
Amarok 2011
00 Technical data
1 Evaluating accident vehicles
(VRL005375; Edition 01.2013)
1.1 Checklist for evaluating running gear on accident vehicles,
page 1
1.1 Checklist for evaluating running gear on

accident vehicles
Damage to running gear may go unnoticed during repairs to load-
bearing and suspension parts of accident vehicles. Under certain
circumstances, this undiscovered damage could lead to serious
consequential damage during later vehicle operation. Therefore,
the following parts of accident vehicles must be examined in the
manner and order described independent of wheel alignment
which may have to be performed. If no deviations from specifica
tions are measured during wheel alignment, there are no defor
mations of the running gear.
Visual and functional examination of steering system
Visual examination for deformation and cracks
Examination for play in track rod joints and steering rack
Visual examination for tears inwboots
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Examine electrical andedhydraulic
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cuts and kinks. ho
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Check hydraulicsslines, threaded connections and steering rack
for leaks.
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Check steering rack and lines for secure seating.

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Check for flawless function from lock to lock by moving the

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steering from stop to stop. In the process, the steering wheel

is n
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must turn with a constant force without resistance.

ole,
spec
Visual inspection and functional check of running gear

t to the co
Adhere to the sequence of the following inspection steps!

Check all components shown in the assembly overviews for
rrectne
deformation, cracks and other damage.

Renew damaged parts.
ss o
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Align wheels on a Volkswagen AG-approved wheel alignment

f in
stand
form
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Visual and functional check of wheels and tyres

om
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Check for true running and imbalance page 86 .

thi
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Check tyres for cuts and impact damage in tread and on flanks.
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page 86
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Check tyre inflation pressure; see tyre inflation pressure stick Cop py
er in fuel tank flap or Maintenance ; Booklet ; Checking tyres:
t. rig
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Condition, profile, inflation pressure, depth of tread
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If rim of wheel and/or tyre is damaged, renew tyre. This also ap
Prote AG.
plies if the circumstances of the accident and the damage to the

vehicle indicate possible damage which is not visible.
A further factor in the decision is the age of the tyre. Tyres should
not be older than 6 years.
1. Evaluating accident vehicles 1

Amarok 2011
If in doubt, the following applies:

Whenever a safety risk cannot be excluded, the tyre(s) must
be renewed.
Entire vehicle
Check other vehicle systems as well, for example:
Brake system including ABS
Visual and functional examination of exhaust system and pas
senger protection
Specifications for testing and adjusting can be found in the re
spective workshop manual in ELSA.
The accident vehicle check described here applies to the running
gear. This makes no claim to completeness for the overall vehicle.
Electronic vehicle systems
Safety-relevant systems such as ABS/EDL; airbags; electronical
ly regulated suspension systems; electromechanical or electro
hydraulic steering and other driver assist systems must be read
with the Vehicle diagnostic tester for possibly stored fault mes
sages. If faults are saved in the event memories of the systems
mentioned above, repair the faults according to the instructions n AG. Volkswagen AG do
in workshop manuals in ELSA. Following repairs, read event olkswage es n
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memories of the affected systems again to ensure that complete byV ua
ed ran
function has been restored. or
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2 Rep. gr.00 - Technical data

Amarok 2011
2 General information
2.1 Tyre types, page 3
2.1 Tyre types

Information concerning wheels, tyres and snow chains can be
found in Wheels and Tyres Guide; Rep. gr. 44 and in Wheels
and Tyres Guide - General Information; Rep. gr. 44 .
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2. General information 3
Amarok 2011
3 Repair instructions
3.1 Steering rack, page 4
3.2 Gaskets and seals, page 4
3.3 Nuts and bolts, page 5
3.4 Electrical components, page 5
3.5 Raising wheel suspension to unladen position,
page 6
3.1 Steering rack

To achieve the desired results when performingarepairs n AG. Von
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steering rack it is important to work with the Vgreatest
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gu
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and cleanliness, and to use proper tools d in
b good condition. Also ara
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note the basic rules on safety when performing
thor repair procedures. eo
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A number of general notes on the
ss individual repair procedures,
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which were otherwise repeated in the relevant sections of the

un
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an
manual, are summarised here. They apply for this particular work
d
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shop manual.
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For a description of the design and function of the APA steering
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system, see Self-study programme No. 399 ; Electromechan
h re
ical Steering with Parallel-axis Drive .
hole
spec
es, in part or in w
For a description of the design and function of the electrome
t to the co
chanical power-assisted steering system, see Self-study pro
gramme No. 317 ; Electromechanical Power-assisted Steering
with Double Pinion .
rrectness of i
Thoroughly clean all unions and the adjacent areas before
l purpos
disconnecting.
When installing the steering rack, make sure that dowel
nform
ercia
sleeves between bracket and steering rack are seated cor

rectly.
m
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com
tion in
Place removed parts on a clean surface and cover them to

r
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prevent them from getting dirty. Use sheeting and paper for
thi
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this purpose. Use only lint-free cloths.

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only immediately prior to fitting.
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Use only the grease and sealants with specified part numbers.
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If repairs cannot be carried out immediately, carefully cover or cted agen
Prote AG.
seal open components.
3.2 Gaskets and seals

Always renew oil seals and seals.
After removing all seals, inspect the contact faces on housings
and shafts for burrs and damage and remove all which are
found.
Completely remove all residue from liquid sealants from the
sealing surfaces, making sure that no residual sealant gets
into the steering rack housing.

Amarok 2011
3.3 Nuts and bolts

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AG. Volkswagen AG d
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Loosen andd btighten
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t gucovers and
ara
housings
orisdiagonally.
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Avoid
ss canting particularly sensitive parts such as servo cmotor
a a
with control unit. Loosen and tighten them diagonally in
ce
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un
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stages.
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Specified torques given are for unlubricated nuts, bolts and
ab
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screws.
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Always renew self-locking nuts and bolts.
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spec
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3.4 Electrical components
At some point, you have probably received an electric shock when
rrectness of i
touching a metal object. This is due to the electrostatic charge
l purpos
accumulated by the human body. This charge can cause mal

functions if you touch the electric steering rack and steering
column components.
nform
ercia
Before working on electrical components, touch an earthed

m
a
object, such as a water pipe or a lifting platform. Do not directly
com
tion in
touch connector contacts.
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3. Repair instructions 5
Amarok 2011 agen
AG. Volkswagen AG d
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Running gear, axles, steering - Edition
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3.5 Raising wheel suspension to unladen th or
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3.5.1 Raising front wheel suspension to unladen position,
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page 6
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3.5.2 Raising rear wheel suspension to unladen position, page , is n
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9
hole
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3.5.1 Raising front wheel suspension to unladen position
es, in part or in w
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Special tools and workshop
rrectness of i
equipment required
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Engine and gearbox jack -

V.A.G 1383 A-
nform
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Tensioning strap - T10038-

m
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Support - T10149-
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AG. Volkswagen AG d
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Amarok 2011
ris
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ho Runningeegear,
or axles, steering - Edition 01.2013
a ac
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Caution
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All bolts on running gear components with bonded rubber
pe
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bushes may be tightened only when the component is in the
wit
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unladen position (normal position) or the vehicle is standing on
h re
hole
its wheels and is unladen.
spec
es, in part or in w
Bonded rubber bushes can be twisted only to a limited extent.
t to the co
Axle components with bonded rubber bushes must therefore
be brought to a position equivalent to the unladen (normal) po
rrectness of i
sition before being tightened.
l purpos
The bonded rubber bushes are otherwise constantly tensioned

and have a shorter service life.
nform
mercia
a
To simulate this position on the lifting platform, raise the respec
com
tio
tive wheel suspension with the engine and gearbox jack - V.A.G
n in
r
1383 A- and support - T10149- .

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Before the axle on one side is raised, both sides of the vehicle
r
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must be strapped to the lifting platform arms with tensioning
fo
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straps - T10038- Maintenance ; Booklet ; Descriptions of work;

t.
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Raising the vehicle .
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WARNING cted agen
Prote AG.
If the vehicle is not strapped down, it may slip off the lifting
platform!
Remove respective wheel.

Turn wheel hub until one of the wheel bolt holes is at the top.
Attach support - T10149- to wheel hub using wheel bolt.
3. Repair instructions 7
Amarok 2011
Respective nuts and bolts may be tightened only when dimension

-a- between the centre of wheel hub and edge of wheel housing
has been attained.
Raise wheel bearing housing using engine and gearbox jack
- V.A.G 1383 A- until dimension -a- is attained.
The dimension -a- depends on the ride height of the installed run
ning gear:
Running gear Ride height -a- in mm
Without wheel house trim 525 17 mm
With wheel house trim 518 17 mm
WARNING
Do not lift or lower vehicle while engine and gearbox jack

- V.A.G 1383 A- is under vehicle.
Do not leave engine and gearbox jack - V.A.G 1383 A-
under vehicle longer than necessary.
Tighten respective nuts and bolts.

Lower wheel bearing housing.
Pull engine and gearbox jack - V.A.G 1383 A- out from under
vehicle.
Detach support - T10149- .
AG. Volkswagen AG d
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Prote AG.

Amarok 2011
3.5.2 Raising rear wheel suspension to unladen position

equipment required
V.A.G 1383 A-
Tensioning strap - T10038-
Support - T10149-
AG. Volkswagen AG d
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Caution
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All bolts on running gear components with bonded rubber

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bushes may be tightened only when the component is in the

h re
hole
unladen position (normal position) or the vehicle is standing on

spec
its wheels and is unladen.

es, in part or in w
t to the co
Bonded rubber bushes can be twisted only to a limited extent.

Axle components with bonded rubber bushes must therefore
rrectness of i
be brought to a position equivalent to the unladen (normal) po

sition before being tightened.
l purpos
Otherwise, the bonded rubber bush would be subject to torsion

loading, shortening its service life.
nform
mercia
at
om
io
To simulate this position on the lifting platform, raise the axle on

n
c
in t
r
one side using the engine and gearbox jack - V.A.G 1383 A- and
o
his
te
support - T10149- .
a
do
priv
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or
Before the axle on one side is raised, both sides of the vehicle
f
en
ng
must be strapped to the lifting platform arms with tensioning

t.
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Cop py
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9
cop Vo
by lksw
Prote
cted AG. 3. Repair instructions
agen
Amarok 2011
straps - T10038- Maintenance ; Booklet ; Descriptions of work;

Raising the vehicle .
WARNING
If the vehicle is not strapped down, there is a danger that the

vehicle will slip off the lifting platform!
Remove respective wheel.

Attach support - T10149- to wheel hub using wheel bolt.
Respective nuts and bolts may be tightened only when dimension
-a- between the centre of wheel hub and edge of wheel housing
has been attained.
Raise wheel bearing housing using engine and gearbox jack
- V.A.G 1383 A- until dimension -a- is attained.
The dimension -a- depends on the ride height of the installed
n AG. Vorun
lkswagen AG
ning gear: lkswage does
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Running gear ho
ir sRide height -a- in mm nte
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Without wheel house trim ss
a
585 17 mm c
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With wheel house trim 578 17 mm

nl
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WARNING
ility
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Never raise or lower the vehicle while the engine and
hole
spec
gearbox jack is positioned beneath the vehicle.
es, in part or in w
t to the co
Do not leave engine and gearbox jack - V.A.G 1383 A-
under vehicle longer than necessary.
rrectness of i
Tighten respective nuts and bolts.
l purpos
Lower wheel bearing housing.

nform
ercia
Pull engine and gearbox jack - V.A.G 1383 A- out from under
vehicle.
m
at
om
io
Detach support - T10149- .

n
c
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or
his
ate
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for
en
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t.
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Cop py
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Prote AG.

Amarok 2011
40 Front suspension
1 Front axle
1.1 Overview - front axle, page 11
1.1 Overview - front axle
1-
4.1 Assembly overview -
suspension strut, upper sus
pension link, page 24
2-
3.1 Assembly overview - agen
AG. Volkswagen AG d
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wheel bearing assembly, olksw not
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page 16 rised b ara
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4.2 Assembly overview - s
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nl
suspension strut, page 26
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4-
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subframe, page 12
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Prote AG.
1. Front axle 11
Amarok 2011
2 Subframe
2.1 Assembly overview - subframe, page 12
2.2 Removing and installing anti-roll bar, page 12
2.3 Renewing anti-roll bar bushes, page 13
2.4 Removing and installing coupling rod, page 15
2.1 Assembly overview - subframe
1 - Ladder frame
2 - Suspension strut
3 - Nut
Always renew after re
moving
110 Nm
4 - Bolt
5 - Coupling rod
Connects anti-roll bar to
trailing arm and wheel
bearing housing
AG. Volkswagen AG d
Removing and installing agen oes
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page 15 . byV gu
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6 - Anti-roll bar aut
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Removing and installing s
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page 12 pt
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7 - Multi-point socket head bolt
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moving
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hole
Tighten new bolts only if the

spec
vehicle is standing on its

es, in part or in w
t to the co
wheels and is unladen or if the

vehicle is raised and is in the
unladen position (normal posi
rrectness of i
tion) . page 6
l purpos
110 Nm
8 - Rubber mounting
nf
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Always replace on both

orm
sides
m
atio
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Allocation Electronic
o
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parts catalogue ETKA

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Removing and installing page 13

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9 - Clamp
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2.2 Removing and installing anti-roll bar

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Prote AG.
Special tools and workshop equipment required
12 Rep. gr.40 - Front suspension

Amarok 2011
Bits - T10099-
Torque wrench - V.A.G 1332-
lkswage es n
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Removing ir se tee
tho
u or
a ac
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Note
un
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The following procedure is for the left side of the vehicle. The
pe
ility
procedure for the right side of the vehicle is identical.

ot
wit
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hole
Unscrew bolt -1- and pull out of anti-roll bar -3-.

spec
es, in part or in w
Unscrew and remove bolts -2- with bit - T10099/1- .

t to the co
Remove anti-roll bar -3- to side.

rrectness of i
Installing
l purpos
Install in reverse order. Note the following points:

Specified torques
nform
ercia

m
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com
tion in
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2.3 Renewing anti-roll bar bushes

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Cop py
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Prote AG.
2. Subframe 13
Amarok 2011
Bits - T10099-
AG. Volkswagen AG d
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Removing s au ra
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Unscrew and remove bolts -2- with bit - T10099/1- .

un
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an
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Pull anti-roll bar clamp off rubber bush.

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Detach rubber bush from anti-roll bar.

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Installing
h re
ole,
spec

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Insert new rubber bush -1- on anti-roll bar via opening

inform
-arrow-.
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atio
om
n
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Note
or
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Ensure that the outer edge of rubber bush -1- lies against stop
p
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-2-.
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Depending on version, the stop -2- can be located on the left
C py
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or on the right of rubber bush.
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Tighten bolted connections to the anti-roll bar only if the vehi
cted agen
Prote AG.
cle is standing on its wheels and is unladen or if the vehicle is
raised and is in the unladen position (normal position)
page 6 .
Specified torques

Amarok 2011
2.4 Removing and installing coupling rod

Torque wrench - V.A.G 1332- AG. Volkswagen AG d
agen oes
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Removing
rrectness of i
Remove bolts -arrows-.
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Remove coupling rod -1-.

Installing
nf
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o
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m
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or c
Note
thi
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sd
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Tighten bolted connections to coupling rod only if the vehicle is cu

o
m
f
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ng
standing on its wheels and is unladen or if the vehicle is raised

t.
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and is in the unladen position (normal position) page 6 . Cop py
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Specified torques by c lksw
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Prote AG.
2. Subframe 15
Amarok 2011
AG. Volkswagen AG d
Running gear, axles, steering - Edition 01.2013 ksw
agen oes
not
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3 Wheel bearing ho eo
aut ra
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3.1 Assembly overview - wheel bearing assembly,
un
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page 16
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3.2 Removing and installing wheel bearing housing,
pe
ility
page 17
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3.3 Removing and installing wheel bearing, page 20
hole
spec
3.1 Assembly overview - wheel bearing assembly
es, in part or in w
t to the co
1 - Wheel bearing
rrectness of i
Black sensor ring faces l purpos
inside of vehicle
Grey slide ring faces
outside of vehicle
nform
ercia
2 - Retaining ring
m
a
com
tio
Ensure proper seating.
n in
r
te o
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3 - Wheel hub
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iva
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4 - Bolt
um
fo
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moving
C py
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150 Nm +180
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5 - Bolt
Prote AG.
9.5 Nm
6 - Bracket
7 - Bolt
8 Nm
8 - Front left speed sensor -
G47- / front right speed sensor
- G45-
Before inserting speed
sensor, clean inner sur
face of fitting hole and
coat it with lubricating
paste Electronic
Parts Catalogue (ET
KA) .
9 - Splash plate
10 - Bolt
9.5 Nm
11 - Wheel bearing housing
Tapered hole must be free of oil and grease.
If necessary, clean with a dry cloth but do not use cleaning solutions.
Removing and installing page 17 .
12 - Tensioning disc
Rear-wheel drive vehicles only
13 - Drive shaft
Four-wheel drive vehicles only

Amarok 2011
AG. Volkswagen AG d
agen oes
lksw not
3.2 Removing and installing wheel bearing housing
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Special tools and workshop s
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equipment required
nl
pt
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Remover - T10103-
erm
ab
ility
ot p
Ball joint puller - T10187-
wit
, is n
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Torque wrench - V.A.G
hole
1332-
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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orm
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Cop py
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Prote AG.
Removing
Lift vehicle far enough to take weight off front axle Mainte
nance ; Booklet ; Descriptions of work; Raising the vehicle .
Vehicles with four-wheel drive
Loosen drive shaft bolt.
Note
Do not move vehicle with loosened bolt. Moving vehicle could

cause damage to wheel bearing.
If vehicle is to be moved with drive shaft removed, an outer
joint must be installed and tightened to 150 Nm.
Continuation for all vehicles

Raise vehicle Maintenance ; Booklet ; Descriptions of work;
Raising vehicle .
Remove wheel.
3. Wheel bearing 17
Amarok 2011
Loosen nut on track rod ball joint but do not remove complete
ly.
Caution
Leave nut screwed on a few turns to protect thread on pin.
Push track rod off wheel bearing housing and remove nut.
1- Ball joint puller - T10187-
wage es n
Unscrew and remove drive shafty Vbolt.
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Press out drive shaft. auth or
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1- Adapter - T10103/1-
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2- Remover - T10103-
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When removing, make sure joints have adequate clearance.
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Remove nut -1- for coupling rod and pull bolt out of suspension
strut.
nf
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Remove bolted joint -2-.

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atio
Remove brake caliper and tie to body using wire Brake

om
systems; Rep. gr. 46 ; Front brake; Removing and installing

n in
or c
brake pads .
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Remove ABS speed sensor Brake systems; Rep. gr. 45 ;

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Sensors; Removing and installing speed sensor .

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Remove brake disc. Cop py
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Remove cover plate. p by
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Remove brake line bracket from wheel bearing housing. Prote AG.
Slacken off nut on tapered pin (but do not remove yet).
Caution
Press out upper suspension link and unscrew nut.


Amarok 2011
Caution
Press out lower suspension link.

Unscrew nut and remove wheel bearing housing.
Installing
Caution
Bonded rubber bushes can be twisted only to a limited

extent.
Therefore, tighten bolted connections on components
having bonded rubber mountings only if the vehicle is
standing on its wheels and is unladen or if the vehicle is
page 6 .
Install wheel and tighten bolts or nuts page 71 .

Specified torques
4.1 Assembly overview - suspension strut, upper suspen
sion link, page 24
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page 16 by
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Cop py
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Prote AG.
3. Wheel bearing 19
Amarok 2011
3.3 Removing and installing wheel bearing

equipment required
Hydraulic press - 6178-
1383A-
Splitter - Kukko 17-2-
Assembly tool - T10205-
Foot pump - 6179-
Drift sleeve - 30-100-
Thrust washer - VW 511-
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Prote AG.

Amarok 2011
Note
When doing this work, always make sure that the tools and
components are in the correct position and, if necessary, use
a second mechanic.
Place engine and gearbox jack - V.A.G 1383 A- below wheel
bearing housing throughout the entire process (to prevent ac
cidents caused by falling parts).
Removing
Remove bolt -1- and remove tensioning disc -arrow- from
wheel bearing housing -2-.
Remove drive shaft page 45
AG. Volkswagen AG d
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Attach gripping pieces - T10205/17 - -3- to wheel hub -1- with

itte
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wheel bolts -2- as shown in illustration.

rm
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Note
hole
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es, in part or in w
Wheel bolts -2- must not protrude from backs of gripping pieces
t to the co
-3-.
rrectness of i
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Mount the tools as shown in illustration.

m
1 - Threaded rod M20 - T10205/8-1

com
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2 - Threaded nut M20 - T10205/8-2

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3 - Press head T10205/13

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4 - Hydraulic cylinder VAS 6178

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6 - Gripping pieces T10205/17
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7 - Press tool T10205/3
8 - Nut M20 - T10205/8-2
9 - Threaded rod M20 - T10205/8-1
Pull hub unit out of wheel bearing housing while holding tool
assembly in place.
Remove retaining ring from wheel bearing.
3. Wheel bearing 21
Amarok 2011
Mount the tools as shown in illustration.

1 - Threaded rod M20 T10205/8-1
2 - Threaded nut M20 T10205/8-2
4 - Support T10205/4
5 - Bell T10205/5
6 - Thrust washer VW 511
7 - Nut M20 T10205/8-2
8 - Threaded rod M20 - T10205/8-1
Hold appliance firmly and pull out wheel bearing.
Fit component and tools as shown in illustration.
Note
Fitting position: Chamfer on plates faces towards inner bearing

race -arrow-.
Pull inner bearing race off hub, using -Kukko 17-2 splitter- to
do so.
Installing
Note
Keep wheel bearing holes free of filings and other contamination.

It is not permissible to oil them additionally before pressing them
in.
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Prote AG.

Amarok 2011
AG. Volkswagen AG d Running gear, axles, steering - Edition 01.2013
agen oes
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Mount the etools y V as shown in illustration. gu
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1 - Threaded
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2 - Threaded nut M20 - T10205/8-2
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3 - Press head T10205/13
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5 - Support T10205/4
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6 - Wheel bearing
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7 - Press tool T10205/6
8 - Nut M20 - T10205/8-2
rrectness of i
9 - Threaded rod M20 - T10205/8-1
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Press in wheel bearing to stop. When doing this, support wheel

bearing housing on shoulder and hold assembly device.
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atio
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Observe mounting direction for wheel bearings. Insert multi-pole
thi
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ring side - ABS in direction of axle shaft.

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Fit retaining ring with opening facing downwards.

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.
Press in hub as far as it will go, using the same arrangement
ht rig
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of tools. When doing this, support inner wheel bearing race.
copy Vo
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Fit tensioning disc.
AG.

Install drive shaft page 45 .
Specified torques
page 16
3. Wheel bearing 23
Amarok 2011
4 Suspension strut, upper suspension

link
4.1 Assembly overview - suspension strut, upper suspension
link, page 24
4.2 Assembly overview - suspension strut, page 26
4.3 Removing and installing suspension strut, page 27
4.4 Removing and installing upper links, page 29
4.5 Renewing bushes for upper suspension link, page 30
4.6 Repairing front suspension strut, page 33
4.7 Removing and installing suspension strut mounting, page
35
4.1 Assembly overview - suspension strut,

upper suspension link
Note
Loose bolted connection in the suspension strut may result in

the piston rod or the lower nut filing an elongated hole into
the suspension turret or the suspension strut mounting.
Volkswa
In this case, deburr the elongated hole
swa in the suspension dturret
gen AG
. gen AG
oes
and apply corrosion protection. yV
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Renew worn parts. hor eo
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If present, remove adhesive residues from the shock absorber
s c
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thread.
un
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an
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Install optimised parts Electronic Parts Catalogue ETKA .

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pe
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If damaged, the new nut Item 6 (page 26) must be bonded

ot
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in with locking fluid Electronic Parts CatalogueETKA .

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spec
es, in part or in w
WARNING
t to the co
rrectness of i
l purpos
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Cop py
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Prote AG.

Amarok 2011
1 - Bolt
moving
50 Nm +90
2 - Nut
moving
25 Nm +45
3 - Stop shell
4 - Bolt
moving
50 Nm +90
5 - Upper suspension link
Tapered pin must be
free of oil and grease.
If necessary, clean with
a dry cloth but do not
use cleaning solutions.
Removing and installing
page 29
6 - Nut
moving
30 Nm +90
7 - Wheel bearing housing
Tapered hole must be
a dry cloth but do not wage
es n
use cleaning solutions. yV
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8 - Nut ir se tee
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Always renew after removingss a ac
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60 Nm +90
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9 - Suspension strut
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10 - Bolt
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spec
11 - Nut
es, in part or in w
Always renew after removing

t to the co
110 Nm +180
12 - Eccentric washer
rrectness of i
13 - Lower suspension link

l purpos
Tapered pin must be free of oil and grease.

nform
ercia
Removing and installing page 37
m
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com
tio
Checking swivel joint page 41 .

n in
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14 - Eccentric bolt
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15 - Nut
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25
Prote AG.
4. Suspension strut, upper suspension link
Amarok 2011
110 Nm +180
16 - Ladder frame
4.2 Assembly overview - suspension strut
Note
Loose bolted connection in the suspension strut may result in

the piston rod or the lower nut filing an elongated hole into
the suspension turret or the suspension strut mounting.
In this case, deburr the elongated hole in the suspension turret
and apply corrosion protection.
Renew worn parts.
If present, remove adhesive residues from the shock absorber
thread. AG. Volkswagen AG d
agen oes
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Install optimised parts Electronic Parts CataloguebETKA
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If damaged, the new nut Item 6 (page 26) must thor be bonded eo
in with locking fluid Electronic Parts CatalogueETKA
ss au
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1 - Bump stop
erm
ab
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2 - Shock absorber
wit
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hole
spec
es, in part or in w
3 - Coil spring
t to the co
Surface of coil must not
be damaged.
rrectness of i
Observe colour coding
l purpos
nf
ercia
4 - Washer
orm
m
atio
5 - Suspension strut mounting
om
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6 - Nut
or
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moving
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25 Nm +45
t.
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Cop py
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Prote AG.

Amarok 2011
4.3 Removing and installing suspension strut

equipment required
Support - T10149-
V.A.G 1383 A-
1332-
Assembly tool - T50042-
Assembly tool - T50042/1-
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es, in part or in w
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Removing
rrectness of i

Raising vehicle .
l purpos
Remove wheel.
nform
ercia
Remove drive shaft page 45

m
To remove left suspension strut

at
om
ion
c
Remove bracket for engine control unit Rep. gr. 23 .

in t
or
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ate
To remove right suspension strut

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Remove air filter Rep. gr. 23

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Cop py
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Prote AG.
4. Suspension strut, upper suspension link 27

Amarok 2011
Continuation for both sides
Note
When the upper nut is loosened, the piston rod must be se

cured against turning.
Otherwise the lower nut can loosen, which will result in sub
stantial noise generation.
Therefore, always use assembly tool - T50042- .
Unbolt suspension strut from frame using assembly tool -

T50042- and remove.
Installing
Note
wage es n
When the upper nut is tightened, y V the piston rod must be se
o lks ot g
cured against turning. d b ua
ran
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ho
Otherwise the lower nuts au can loosen, which will result in sub
t or
ac
stantial noise generation.
s
ce
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nl
pt
du
Therefore, always use assembly tool - T50042- .

an
itte
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erm
ab
ility
ot p
Secure suspension strut to frame using assembly tool -

wit
, is n
T50042- . h re
hole
spec
es, in part or in w
Caution
t to the co

extent.
rrectness of i

l purpos

nf
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or
page 6 .
m
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Specified torques
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4.2 Assembly overview - suspension strut, page 26
Co
Cop py
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sion link, page 24
co Vo
by lksw
cted agen
Prote AG.
page 16

Amarok 2011
4.4 Removing and installing upper links

equipment required
Support - T10149-
V.A.G 1383 A-
1332-
AG. Volkswagen AG d
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Removing
c by lksw
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Raising vehicle .
Remove wheel.
Attach support - T10149- with a wheel bolt -A-.

Amarok 2011
Caution

AG. Volkswagen AG d
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Remove bolts -arrows- and removeisupper
ed b suspension link. ara
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Installing s aut ra
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Caution
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hole
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es, in part or in w
t to the co
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page 6 .
l purpos
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Specified torques
m
a
com
4.1 Assembly overview - suspension strut, upper suspen tion in

sion link, page 24
r
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4.5 Renewing bushes for upper suspension

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Special tools and workshop equipment required yri
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Thrust plate - VW 402-
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Prote AG.

Amarok 2011
-- Tube - VW 426-
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Drift sleeve - 40 - 21-
rm
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Thrust piece - VW 454-
com
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Removal wedge - 3409-

Chisel
Metal saw
Note
When doing this work, always make sure that the tools and com
ponents are in the correct position and, if necessary, use a second
mechanic.
Removing
Remove upper suspension link. page 29
Clamp upper suspension link in a vice.

AG. Volkswagen AG d
Amarok 2011 agen oes
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Always use suitably padded jaws in order to avoid damage to the
erm
ab
component.
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Use a chisel to bend metal collar up 3 mm. Then, saw off the
hole
spec
metal collar.
es, in part or in w
t to the co
Place component and tools in position as shown in illustration.
rrectness of i
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Press out bush together with tube - VW 426 - .

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Place component and tools in position as shown in illustration. C py
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Use removal wedge - 3409- to push rubber lip into the sus
p by
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pension link. Prote
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agen
Press bush in flush.

Install upper suspension link. page 29
Specified torques
sion link, page 24

Amarok 2011
4.6 Repairing front suspension strut

equipment required
Shock absorber set -
T10001-
Torque wrench -
V.A.G 1332-
Spring compressor - VAS
6046-
Spring retainer - VAS
6046/3-
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es, in part or in w
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tion in
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Remove coil spring strut page 27 .

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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011
Removing coil spring

Tension coil spring until upper suspension strut mounting is
free.
Unscrew hexagon nut from piston rod.
Remove individual parts of strut and coil spring using spring
tensioner - VAS 6046- and spring retainers - VAS 6046/3- .
1 - Commercially available ratchet handle AG. Volkswagen AG d
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3 - -T10001/11- ut
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5 - -VAS 6046-
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6 - -VAS 6046/3-
ility
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WARNING
hole
spec
es, in part or in w
First compress spring far enough to ensure that upper spring
t to the co
plate is free.
rrectness of i
Ensure that coil spring is correctly seated in spring retainer -
l purpos
VAS 6046/3- -arrow-.

Installing coil spring
nform
mercia
at
om
ion
c
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Cop py
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rig ht
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Prote AG.
Set bottom of coil spring on spring retainer - VAS 6046/3- .
Ensure that coil spring is correctly seated in spring retainer -
VAS 6046/3- -arrow-.
Clamp coil spring.

Amarok 2011
Fit coil spring with suspension strut tensioner - V.A.G 1752-

onto bottom spring plate.
The end of the coil spring must lie against the stop -arrow-.
Position disc and suspension strut mounting on spring.

End of coil spring must lie against stop of suspension strut mount
ing -arrow-.
Tighten new hexagon nut on piston rod.
Note
Nut must be screwed on in tensioned state. The mounting se

quence must be complied with. en AG. V
olkswagen AG
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Relieve tension on spring compressor - VAS 6046- ed
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Install suspension strut page 27 . ss
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nl
pt
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Specified torques
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erm
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ility
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sion link, page 24
wit
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hole
4.7 Removing and installing suspension
spec
es, in part or in w
strut mounting
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
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Cop py
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Prote AG.

Amarok 2011
Tube - VW 415 A-
Tube - 2040-
AG. Volkswagen AG d
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es, in part or in w
t to the co
Removing
Remove lower suspension link page 37 .
rrectness of i
l purpos
Press out suspension strut mounting downwards with tube -

2040- .
nf
ercia
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Installing
rm
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Cop py
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rig ht
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Prote AG.
Fit mounting from above and press in flush, together with tube
- 2040- .
Install lower suspension link page 37 .
Specified torques
sion link, page 24

Amarok 2011
5 Lower suspension link, swivel joint

5.1 Removing and installing lower suspension link,
page 37
5.2 Renewing bonded rubber bush for lower suspension link,
page 39
5.3 Checking swivel joint, page 41
5.1 Removing gand AG.installing

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Removing
Raising vehicle .
Remove wheel.
Remove nut -1- for coupling rod and pull bolt out of suspension
strut.
Remove bolted joint -2-.
5. Lower suspension link, swivel joint 37

Amarok 2011 AG. Volkswagen AG d
agen
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Slacken off nut on tapered pin (but do notutremove
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Press out lower suspension link and unscrew nut.
spec
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rrectne
Loosen bolted joint -1-.
ss
Remove bolted joint -2- and move lower suspension link down
o
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a little in -direction of arrow-.
inform
mer
Remove bolt -1-.
atio
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Move lower suspension link down and thread out of wheel
c
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bearing housing.
thi
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extent.
page 6 .

Do not tighten threaded connection between lower suspen
sion link and ladder frame until during wheel alignment.
Perform wheel alignment page 77 .
Specified torques
sion link, page 24

Amarok 2011
5.2 Renewing bonded rubber bush for lower suspension link

equipment required
Thrust plate - VW402-
Press tool - VW 408 -
Press tool - VW 411-
Tube - VW 40-20-
Thrust washer - VW 447 i-
Installing sleeve - VW 455-
Assembly tool - 3346-
Tube - 30-14- AG. Volkswagen AG d
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Prote AG.

Amarok 2011
Front rubber bush

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When doing this work, always make sure that the tools and com
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ponents are in the correct position and, if necessary, use a second
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Remove lower suspension link. page 37
h re
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spec
es, in part or in w
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Press out bush together with tube -VW 415 A-.
Installing
rrectness of i
l purpos
nform
mercia
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tion in
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Push in bush together with -VW 415 A- until it is flush.

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In order to achieve more precise flush-mounting at the end of the

pressing-in process, the removal tube - 3014- can be used as
shown in the preceding illustration.
Install lower suspension link. page 37

Rear rubber bush
Removing
Remove lower suspension link. page 37
Note
When doing this work, always make sure that the tools and
components are in the correct position and, if necessary, use
a second mechanic.
Remove rubber edge -arrow- before pressing out bush.

Amarok 2011
Use press tool - VW 408- to press out bush.

Installing
Place bush in assembly tool - 3346/1- .
Use press tool - VW 410- and thrust washer - VW 447- to force

the lower suspension link on over the bush.
Note
The additional thrust plates -VW 402- are used for height com
pensation during the pressing-in process so that the suspension
link does not become slanted.
Install lower suspension link. page 37

Specified torques
sion link, page 24
5.3 Checking swivel joint

The check must be carried out with the vehicle
wage
raised.
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Checking axial play ed by ara
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Raise vehicle Maintenance ; Booklet ; Descriptions of work; eo
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Raising vehicle . ss c
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Prote AG.

Amarok 2011
Checking radial play

Set wheels/steering to straight-ahead position.
Grip wheel at top and bottom and wobble in
-direction of arrow-.
Turn wheels/steering to left and repeat check.
Turn wheels/steering to right and repeat check.
Note
AG. Volkswagen AG d
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There should be no palpable or visible play during both tests.
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Take into account possible existing wheel bearingorplay
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Other methods of checking are impermissible, as the swivel
ce
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joint may otherwise be damaged.
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Amarok 2011
6 Drive shaft AG. Volkswagen AG d

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6.2 Removing and installing drive shaft,
hor page 45 eo
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6.3 Dismantling and assembling drive
ss
shaft, page 48
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6.4 Checking outer constant velocity joint, page 51
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6.1 Assembly overview - drive shaft
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Only vehicles with four-wheel drive
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1 - Bolt
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150 Nm +180
l purpos
When bolt is loosened or tight

ened, vehicle must not be
standing on its wheels.
nform
mercia
2 - Outer constant velocity joint
a
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Renew only as com
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3 - Retaining ring
moving
Insert in groove in shaft
4 - Clamp
moving
Tightening page 51
5 - Boot
Check for splits and
chafing
Material: Hytrel (poly
ester elastomer)
6 - Clamp
moving
Tightening page 51
7 - Drive shaft
8 - Multi-point socket head bolt
Initial torque specification: 10 Nm
50 Nm +90
6. Drive shaft 43
Amarok 2011
9 - Locking plate
10 - Clamp
Tightening page 51 agen
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11 - Boot for constant velocityedjoint
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Material: Arnitel (polyester
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Check for splits and chafing
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Drive off constant velocity joint with a drift
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Before installing to constant velocity joint, coat sealing surface with sealant Electronic Parts Catalogue
ility
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12 - Clamp
spec
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Tightening page 51
13 - Inner constant velocity joint
rrectne
Renew only as complete unit
Pressing off page 50
ss o
Pressing on page 50
cial p
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14 - Retaining ring
mer
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Remove and install with circlip pliers - VW 161 A-
om
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15 - Cover
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Prote AG.

Amarok 2011
6.2 Removing and installing drive shaft

equipment required
Remover - T10103-
Support - T10149-
Torque wrench -
V.A.G 1332-
V.A.G 1383 A-
Torque wrench -
V.A.G 1601-
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Lift vehicle far enough to take weight off front axle Mainte
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nance ; Booklet ; Descriptions of work; Raising the vehicle .

spec
Loosen drive shaft bolt.

t to the co
Note
rrectne
Tighten or loosen bolt only when vehicle is standing on its

ss
wheels (danger of accident!).

o
cial p
f inform
Do not move vehicle with loosened bolt. Moving vehicle could

mer
cause damage to wheel bearing.

atio
om
If vehicle is to be moved with drive shaft removed, an outer

c
i
or
joint must be installed and tightened to 150 Nm.

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Prote AG.
6. Drive shaft 45
Amarok 2011
ly.
Caution
Unscrew and remove drive shaft bolt.
Press out drive shaft.

1- Adapter - T10103/1-
2- Remover - T10103-
When removing, make sure joints have adequate clearance.
Pull connector off ABS speed sensor.
Remove brake line bracket from wheel bearing housing.
AG. Volkswagen AG d
Remove nut -1- for coupling rod and pull bolt out
wageof suspension
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Remove bolted joint -2-. tho eo
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Unbolt drive shaft from final drive.
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Attach support - T10149- with a wheel bolt -A-.

rrectness o
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Amarok 2011
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Running
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Caution
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Lower wheel bearing housing until drive shaft can be removed.
rrectness of i
Remove drive shaft.
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Installing
nf
Install in reverse order. Note the following points: ercia
orm
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Note
or
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Tighten bolted connections between lower suspension link and

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suspension strut only if the vehicle is standing on its wheels and
f
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is unladen or if the vehicle is raised and is in the unladen position
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Install wheel and tighten bolts or nuts page 71 . cted agen
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Specified torques
sion link, page 24
page 16
6. Drive shaft 47
Amarok 2011
6.3 Dismantling and assembling drive shaft

equipment required
Press tool - VW 408 A-
Support sleeve - VW 522- AG. Volkswagen AG d
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Tensioner - 40 - 204 A- by Vol not
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Special pliers - V.A.G 1682-thor eo
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es, in part or in w
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rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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Prote AG.
Multi-purpose tool - VW 771-

Amarok 2011
Puller - T10382-
Removing outer constant velocity joint

Clamp drive shaft in vice using protective jaw covers.
Fold back boot. AG. Volkswagen AG d
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Set puller - T10382- by
V up so that smooth side of puller
ol not
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T10382/1- pointsrised to spindles - T10382/2- . ara
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Assemble s aupuller - T10382- complete with multi-purpose tool
ra -
c
VW 771- .
s
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Pull constant velocity joint from drive shaft with puller -

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T10382- and multi-purpose tool - VW 771- .
erm
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1- Puller plate - T10382/1- wit

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2- Spindles - T10382/2-
hole
spec
Driving on outer constant velocity joint

es, in part or in w
t to the co
Install new retaining ring.

If necessary, push new joint boot onto drive shaft.
rrectness of i
Knock onto shaft with plastic hammer until circlip engages.

l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
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for
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Driving off cover for inner joint Cop py
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Remove retaining ring. p by
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Remove both clamps and slide boot towards outer joint. Prote AG.
Drive off boot with drift.
6. Drive shaft 49
Amarok 2011
Pressing off inner constant velocity joint

Assembling
Pressing on inner constant velocity joint

Press joint on to stop.
Install retaining ring.
Coat sealing surface of cover with sealant Electronic Parts

AG. Volkswagen AG d
Catalogue (ETKA) . lksw
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Apply a continuous bead of sealant with a 2 ... 3 mm to clean
rise
d b ara
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surface of cover in area of inner holes -arrow-. utho eo
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hole
spec
es, in part or in w
t to the co
Using bolts -arrows-, align new cover in relation to bolt holes.
The alignment must be very accurate, because no further align rrectness of i
ment is possible once the part has been hammered on.
l purpos
Drive on cover using a plastic hammer.

Wipe off surplus sealant.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
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t.
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Cop py
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by
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Prote AG.

Amarok 2011
Tighten clamp on outer joint

Position clamp tensioner - V.A.G 1682- as shown in diagram.
Ensure jaws of tensioner lie in corners -arrows B- of ears on
O-type clip.
Tighten clamp by turning spindle with a torque wrench (do not
cant pliers).
Specified torque
Component Specified torque
Clamp 25 Nm
Note
Due to the hard material of the protective boot (compared to

rubber) and the necessity of using a stainless steel clamp, it
is only possible to tension the clamp with clamp tensioner -
V.A.G 1682- .
Use torque wrench -C - with setting range of 5 ... 50 Nm (e.g.
torque - V.A.G 1331- ).
Make sure thread of spindle -A- on pliers moves freely. Lubri
cate with MoS2 grease if necessary.
If the thread is tight (e.g. due to dirt), the required clamping
force for the clamp will not be attained although the specified
tightening torque is applied.
AG. Volkswagen AG d
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Tightening clamp on small ris diameter
ed
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6.4 Checking outer constant velocity joint

s
The joint is to be dismantled to renew the grease if it is heavily

s o
soiled, or to check the running surfaces of the balls for wear and
cial p
f in
damage.
form
mer
atio
Removing
om
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c
Before dismantling, mark position of ball hub in relation to ball

or
n thi
e
cage and joint body with an electric scriber or oil stone.

t
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pr
Swing ball hub and ball cage.

um
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fo
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Remove balls one at a time.
Co
Cop py
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Prote AG.
6. Drive shaft 51
Amarok 2011
Turn cage until the two rectangular windows -arrow- lie on joint
body.
Take out cage with hub.
Swing segment of hub into square cage window.

Tip hub out of cage.
The six balls for each joint belong to a tolerance group. Check
stub axle, hub, cage and balls for small indentations (pitting) and
traces of seizing. Too much circumferential backlash in the joint
becomes noticeable during load change jolts; in such cases, the
joint must be renewed. Smoothing and traces of wear of the balls
are no reason to change the joint.
Installing
Pack half the total quantity of grease into the joint body.
Fit cage with hub into joint body.
AG. Volkswagen A gen G do
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Press in opposing bballs
y V one after the other; the original
olk not position
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of the hub relative
ris
e to the cage and joint body must be restored.
d ara
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Fit new retaining
sa
u ring into hub. ac
s
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Distribute remaining grease in boot.

un
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ility
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t to the co
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cial p
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mer
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Prote AG.

Amarok 2011
42 Rear suspension
1 Rear axle
1.1 Overview - rear axle, page 53
1.2 Assembly overview - rear axle, page 54
1.3 Assembly overview - rear axle shafts, page 56
1.4 Removing and installing bump stop for leaf spring,
page 57
1.5 Removing and installing rear axle, page 57
1.6 Removing and installing leaf spring, page 60
1.7 Renewing rubber bush for leaf spring, page 64
1.8 Removing and installing plastic insert for leaf spring, page
66
1.9 Removing and installing rear axle shaft, page 66
1.1 Overview - rear axle
I-
rear axle, page 54
II -
rear axle shafts, page 56
AG. Volkswagen AG d
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es, in part or in w
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tion in
r
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thi
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do
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Cop py
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Prote AG.
1. Rear axle 53
Amarok 2011
1.2 Assembly overview - rear axle
Note
It is not permitted to carry out welding and straightening operations on load-bearing or wheel-guiding sus
pension components.
Always renew self-locking nuts.
Always renew corroded nuts and bolts.
Bonded rubber bushes can be twisted only to a limited extent. Therefore, tighten the bolted connections of
components with bonded rubber bushes only when the wheel bearing housing is raised to unladen position
page 6 .
Always renew bonded rubber bush on both sides of the vehicle.
1 - Bolt
moving
90 Nm +180
2 - Nut
moving
90 Nm +180 lkswage es n
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3 - Clamp ir se nte
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4 - Stone deflector
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5 - Bolt
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6 - Bump stop
erm
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ility

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page 57
, is n
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7 - Nut
spec
es, in part or in w

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moving
90 Nm +180
rrectness of i
8 - Shock absorber
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Parts Catalogue ET
KA .
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ercia

m
page 69
at
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9 - Bolt
or
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10 - Shackle
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11 - Bolt
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43 Nm
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12 - Spring retainer
13 - Final drive cover
14 - Seal
54 Rep. gr.42 - Rear suspension

Amarok 2011
. Volkswagen AG
gen AG does
15 - Axle beam Vol
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Removing and installing page
ris
ed57 .
b ara
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16 - Leaf spring au ra
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ss
Allocation Electronic Parts Catalogue ETKA .
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ab
17 - Propshaft
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ot
Before removing, mark position relative to final drive flange.
wit
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hole
18 - Bolt
spec
es, in part or in w
t to the co
50 Nm +90
19 - Bolt
rrectness of i
Shorter than Item 11 (page 54)
l purpos
43 Nm
20 - Bolt
nform
ercia
32 Nm
m
a
com
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21 - Oil drain plug
on in
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23 - Bolt
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90 Nm +180
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24 - U bolt
25 - Saddle plate
26 - Nut
150 Nm +180
1. Rear axle 55
Amarok 2011
1.3 Assembly overview - rear axle shafts
1 - Rear axle
2 - Bolt
moving
150 Nm +90
3 - Bolt
moving
Clean locking fluid resi AG. Volkswagen AG d
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spec
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30 Nm
4 - Brake carrier
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5 - Rear axle shaft
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With wheel bearing unit

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Allocation of rear axle shafts
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The rear axle shafts are colour-coded. Observe proper installation
without exception:
A: yellow marking for left shaft in direction of travel
B: blue marking for right shaft in direction of travel

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Amarok 2011
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Removing and installing bump stop -1- for leaf spring
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To remove, position a screwdriver -2- at side between bump
ility
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Compress bump stop in -direction of arrow- and remove.
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When installing bump stop, compress it with a screwdriver
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-2- in -direction of arrow- and insert in support on frame.
rrectness of i
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1.5 Removing and installing rear axle

nform
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Engine and gearbox jack - V.A.G 1383 A-

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Removing
Raising vehicle .
Remove wheels.
Note
The following procedure is for the left side of the vehicle. The
procedure for the right side of the vehicle is identical.
1. Rear axle 57
Amarok 2011
Loosen nuts -1- approx. 2 turns.
lkswage es n
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Disconnect brake hose -1- from brake line -arrow-.
ir se
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Unscrew adjustment nut -5- from front handbrake cable -1-.
l purpos
Unhook handbrake cable at rear left -2- and right -3- from
compensator -4-.
nform
ercia
Press the two locking projections together at control cable

support bracket -arrow B- of handbrake cable, e.g. using pli
m
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on in
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Remove handbrake cable from control cable support bracket.
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Prote AG.
Pull handbrake cable -A- out of brackets on ladder frame and

body -arrows- and remove.

Amarok 2011
Remove all cable ties -arrows- for speed sensor wire from
handbrake cable.
Disconnect speed sensor connector for ABS.
If present, disconnect connector -1- and pull it off bracket.

Pull vent pipe -2- off final drive.
Unbolt propshaft from propshaft flange of final drive.
Pull propshaft off propshaft flange and secure it.
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Place engine and gearbox hjackrise - V.A.G 1383 A- under axle nte
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beam and tie it down with
s a tensioning belt of universal mount
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spec
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Unfasten bolted joint of shock absorber -1- on rear axle

l purpos
-arrow-.
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tion in
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Cop py
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1. Rear axle 59
Amarok 2011 agen
AG. Volkswagen AG d
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Unscrew nuts -1- from U bolts -2- and -3-. auth or
ac
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Remove U bolts and saddle plate.
ce
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Lower rear axle with engine and gearbox jack - V.A.G 1383
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ab
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Caution
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extent.
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com
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Only use new securing bolts and securing nuts. t. C rig
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Make sure that guide pin of leaf spring engages in hole in axle
co Vo
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beam.
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Prote AG.
Tighten them both uniformly so that the same length of thread

protrudes in each case.
Mount propshaft on propshaft flange.
Note
Make sure that marks on flange and shaft align.
Install wheels and tighten bolts or nuts page 71 .

Specified torques

Brake hose to brake line 14 Nm
1.6 Removing and installing leaf spring


Amarok 2011
lkswage es n
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Torque wrench - V.A.G 1601- ss
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Removing
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Raising vehicle .
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Remove wheel.
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Remove wheel housing liner General body repairs, exterior;

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Rep. gr. 66 .
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Position engine and gearbox jack - V.A.G 1383 A- beneath
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axle beam and exert slight counter pressure.
C py
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Unfasten bolted joint of shock absorber -1- on rear axle
cop Vo
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-arrow-.
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Prote AG.
1. Rear axle 61
Amarok 2011
Unscrew nuts -1- from U bolts -2- and -3-.

Remove U bolt and saddle plate from leaf spring.
In order to remove front bolt of leaf spring -1-, it is necessary

to remove cover cap -arrow-.
lkswage es n
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Unscrew and remove front bolt -arrow- of leaf spring -1-.
ot p
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spec
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rrectness of i
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nform
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at
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ion
c
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or
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ate
do
priv
cum
for
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t.
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Cop py
t. rig
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by
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Prote AG.

Amarok 2011
Unscrew and remove rear bolt -arrow- of leaf spring -1-.

Lower axle beam to approx. 20 mm.
Note
Leaf spring guide pin must slide out of hole in axle beam; lever
out if necessary.
Watch out for brake hose. It must not be stretched.
Remove leaf spring to side.

Installing AG. Volkswagen AG d
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Install in reverse order.by V Note the following points: t gua
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pt
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spec
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page 6 .
t to the co
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Note
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Only use new securing bolts and securing nuts.

nform
ercia
Make sure that guide pin of leaf spring engages in hole in axle
beam.
m
at
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Tighten them both uniformly so that the same length of thread

in t
or
protrudes in each case.

his
ate
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Install wheels and tighten bolts or nuts page 71 .

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Specified torques C py
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Prote AG.
1. Rear axle 63
Amarok 2011
1.7 Renewing rubber bush for leaf spring

equipment required
tool - VW 459/2-
Tube - 40-203/1-
Assembly tool - T10230/9-
lkswage es n
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Removing and installing front leaf spring mounts
Removing ss o
cial p
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Remove leaf spring page 60 .

nform
mer
atio
om
n
c
i
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pr
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fo
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t.
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Cop py
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Prote AG.

AG. Volkswagen AG d
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Volksw not
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Amarok 2011
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rise
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Running
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tho eo
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Use a sharp
ss chisel to remove metal collar from bonded rubber c
bush in order to support leaf springs.
ce
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un
pt
an
d
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Remove rubber edge -arrow- of bush.
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spec
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mer
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Press out bonded rubber bush.
um
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Installing
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Cop py
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Pressing in bonded rubber bush.

Removing and installing rear leaf spring mounts
Removing
Remove leaf spring page 60 .
Note
The rear shackle can only be replaced as a complete part.
Press out bonded rubber bush.

Installing
1. Rear axle 65
Amarok 2011
Pressing in bonded rubber bush.
1.8 Removing and installing plastic insert for

leaf spring
Removing
Unscrew bolt -arrow- and remove sleeve -1-.
WARNING
Do not damage plastic sleeve.

AG. Volkswagen AG d
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Release plastic insert -1- and carefully pull off bracket in
pe
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-direction of arrow-.
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Installing
hole
spec
es, in part or in w
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Note
rrectness of i
Before installing new insert, remove soiling on guides of bracket.
l purpos
Slide plastic insert onto bracket, they must audibly and per
nform
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ceptibly engage.
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1.9 Removing and installing rear axle shaft

r
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Cop py
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Prote AG.

Amarok 2011
Removing
Raising vehicle .
Remove wheel.
Pull connector -2- off speed sensor -1-.
Remove bolt -arrow-.

Pull speed sensor out ofnaxle
wage
beam.
AG. Volkswagen AG
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Vol t
Remove brake d b drum Brake systems; Rep. gr. u46
y g
ara ; Rear
rise
brake; Resetting drum brake . nte
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au ac
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pt
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t to the co
Place a container under area of rear axle shaft to collect oil.

rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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ng
t.
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Cop py
t. rig
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pyri by
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by
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Prote
67
AG.
1. Rear axle
Amarok 2011
Screw a bolt -2- approx. 100 mm in length through one of

wheel bolt threads in wheel hub -1-.
Screw in bolt -2- until it makes contact with bolt for brake carrier
-arrow-.
Turn bolt -2- until rear axle shaft can be removed with wheel
hub -1-.
Installing
Note
Observe fitting instructions! page 56
Vehicles with drain plate:
Note
Clean drain plate before reinstalling rear axle shaft.
When installing rear axle shaft, drain plate -arrow- must be

guided through brake carrier.
The drain plate faces downwards in this step.
Continuation for all vehicles:
Specified torques
1.3 Assembly overview - rear axle shafts, page 56
AG. Volkswagen AG d
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t to the co
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cial p
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mer
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n
c
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or
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fo
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t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Amarok 2011
2 Suspension strut, shock absorber,

spring
2.1 Removing and installing shock absorbers, page 69
2.1 Removing and installing shock absorb

ers
AG. Volkswagen AG d
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d by ara
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nf
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orm
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or c
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Removing
o
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Raise vehicle Maintenance ; Booklet ; Descriptions of work; Cop py
Raising vehicle .
t. rig
gh ht
pyri by
Vo
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by c
Position engine and gearbox jack - V.A.G 1383 A- beneath
lksw
cted agen
Prote
axle beam and exert slight counter pressure.
AG.
Unfasten lower bolted joint of shock absorber -1- on rear axle

-arrow-.
2. Suspension strut, shock absorber, spring 69

Amarok 2011
Unfasten upper bolted joint of shock absorber -1- on ladder

frame -arrow-.
Remove shock absorber.
Installing lkswage es n
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Install in reverse order. Note ir sethe following points:
d b ran
tee
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Caution s
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spec
es, in part or in w
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page 6 .
rrectness of i
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Note
If the shock absorbers are renewed, the plastic stone guards
nform
ercia
on some shock absorbers must be transferred to the new

m
units.
a
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tion in
The plastic stone guard must be renewed if damaged.
r
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Specified torques
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t.
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Cop py
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Prote AG.

Amarok 2011
44 Wheels, tyres, vehicle geometry

1 Wheels, tyres
1.1 Torque settings for wheel bolts, page 71
1.2 Pressing tyre off wheel rim, page 71 agen
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1.3 Removing tyre from wheel, page 72 ed by
V gu
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1.4 Fitting tyres, page 73 aut
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1.5 Wheel change, protecting wheel centring seat against cor
ce
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rosion, page 73
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1.6 Wheel change, installation requirements, page 73 erm
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1.7 Wheel change, installation instructions for wheel change,
wit
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page 75
h re
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spec
1.8 Wheel change, wheel installation, page 76
es, in part or in w
t to the co
1.1 Torque settings for wheel bolts
Specified torque
rrectness of i
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Wheel bolt to wheel hub for all vehicles 180 Nm
nform
mercia
at
om
i
Before fitting wheel, protect wheel centring seat against cor
on
c
rosion page 73 .
in t
or
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ate
1.2 Pressing tyre off wheel rim
do
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New wheels with a modified contour have been introduced for all
n
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vehicles as of model year 2005. C py
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The tyre fitting unit must be furnished with the tyre fitting head
p by
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designed for these wheels. Prote
cted AG.
agen
WARNING
Otherwise there is a danger of the wheel being damaged.
If the tyre fitting unit has not yet been modified, please contact the
manufacture of the unit.
Notes on safety and conditions for removing and fitting tyres
(wheels with tyre pressure monitoring)
It is extremely important to adhere to the instructions and
warnings in the following descriptions.
Check whether the tyre pressure sensor should also be re
placed Vehicle diagnostic tester.
Note
Ensure that the tyre does not contact the tyre pressure sensor
during removal or fitting.
The tyre pressure sensor must not come into contact with wa
ter or be blown upon with compressed air when the wheel is
cleaned.
1. Wheels, tyres 71
Amarok 2011
Remove air from tyre by screwing out the nickel-plate valve

element.
When pressing off a tyre using tyre fitting equipment with a
press-off plate, always ensure that the tyre valve/ tyre pres
sure sensor -arrow- is directly opposite the bead breaker -1-.
The bead breaker must be positioned no more than 2 cm from
wheel rim flange.
Remove balancing weights and dirt from wheel rim.
Press both tyre beads off all round and liberally coat tyre and
wheel rim flange with tyre assembly paste -arrow-.
WARNING
Otherwise, there is a risk of damaging the rim.
If the tyre fitting unit has not yet been modified, please contact the
manufacture of the unit.
AG. Volkswagen AG d
agen oes
olksw not
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1.3 Removing tyre from wheel d b ara
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Tyres which have been filled or sealed using tyre sealant must
ss a be c
drained before removal.
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nl
pt
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itte
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Caution
ab
ility
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Avoid eye and skin contact with tyre sealant.
h re
hole
It is a health hazard and may cause eye irritation and al
spec
lergies.
es, in part or in w
t to the co
During this work, wear protective gloves and safety gog
gles.
rrectness of i
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Place the wheel on an even surface.

Unscrew and remove the valve insert of tyre valve.
nform
ercia
Use a suitable drill or mill to carefully drill a hole in shoulder

m
at
area of tyre.
om
ion
c
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Hold wheel over a suitable container and drain sealant.

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ate
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Remove tyre from wheel.

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Clean wheel rim with, for example, a moist cloth.

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Cop py
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rig ht
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by lksw
cted agen
Prote AG.
72 Rep. gr.44 - Wheels, tyres, vehicle geometry

Amarok 2011
1.4 Fitting tyres

Ensure that the wheel rim is clean.
Insert new tyre valve with -VAS 6459- -1-.
Unscrew and remove valve insert.
Inflate tyre to approx. 3 to 4 bar. The bead of the tyre must slip
audibly over the hump of the rim.
Screw in valve insert.
Check tyre pressure to make sure prescribed pressure has
been reached.
Balance wheel.
1.5 Wheel change, protecting wheel cen

tring seat against corrosion
Applies to alloy and steel wheels
When changing a wheel, wheel centring seat should be waxed
using wax spray Electronic parts catalogue (ETKA) to prevent
corrosion between wheel centring seat and wheel.
Remove wheel.
Thoroughly clean wheel centring seat on wheel hub and cen
tring of rim.
Apply wax to centring area -arrow- with a brush.
WARNING
Wheel bolts, contact surfaces of wheel hub and wheel, brake

discs and threads of wheel hub must not be waxed. Never treat
wheel securing bolts with lubricant or corrosion protection ma agen AG. Volkswagen AG do
terials! Vol
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Install wheel and tighten bolts or nuts page 71 au
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ac
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1.6 Wheel change, installation require

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ments
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Warming cold tyres to minimum installation temperature

spec
es, in part or in w
t to the co
Note
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This instruction also applies to ultra-high performance tyres

(height/width ratio smaller than/same as 45 % and speed symbol
l purpos
greater than/same as V).

nform
ercia
WARNING
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com
tion in
The minimum installation temperature of a tyre should be be

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thi
tween 15 C and 30 C in the core of the tyre.

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Cop py
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73
co Vo
by lksw
cted
1. Wheels, tyres
agen
Prote AG.
Amarok 2011
To install tyres without damage, it is especially important to

warm the upper part of the sidewall and the inside of the upper
bead to at least 15 .
This internal temperature is referred to as the core tempera
ture.
. Volkswagen AG
does gen AG
Rubber is a poor conductor Vofolheat.
ksw Therefore, a cold tyre
a must
not
be left in an area with the d bcorrect temperature for a sufficiently
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ar
long period so the inner rise rubber layers can warm up to at least ante
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15 C. sa
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s
The surface temperature of the tyre during the warming up
ce
le
un
pt
phase is no indication of its internal temperature.
an
d
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erm
ab
To enable cold tyres to absorb heat from the ambient air as
ility
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quickly as possible, they should not be stacked on top of one
wit
is n
another but instead stored individually in order to allow the
h re
warm air to circulate around them effectively.
ole,
spec
Tyres must never be placed in front of a radiator or hot air
t to the co
blower for warming, since this can very quickly lead to critical
surface temperatures.
Except for warming with warm water or warm air (max. 50 ),
rrectne
there is no process available for warming tyres without dam
aging the tyre!
ss o
When cold tyres (below 0 ) are transferred to a warm envi
cial p
f in
ronment (above 0 ), a layer of condensation immediately
form
mer
forms on the surface of the tyre. This layer of condensation
atio
indicates that the tyre is intensively absorbing heat from its
om
environment through the process of water vapour in the air n

c
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or
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condensing out on the tyre surface.
te
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Once the layer of frost has thawed, condensate water forms.

p
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The condensation should be dried with a cloth so that the fur

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ther warming process is not delayed due to a temperature drop
Co
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caused by evaporation.
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Warming times:
co lksw
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cted agen
Prote AG.
Assuming a minimum room temperature of 19 and a tyre
temperature of 0 or more, a tyre should be kept at least at
19 for at least 2 hours
Assuming a minimum room temperature of 19 and a tyre
temperature of below 0 C, a tyre should be kept at least at 19
for at least 2.5 hours
Warming recommendations:
If possible, tyres should be stored in the workshop 1 day before
they are fitted (order preparation).
Store on an insulated base, pallet or the like, as high up as
possible
Position the tyres individually to allow the warm air to circu
late around them effectively.
Wipe off perspiration water.
Never heat with a radiator or hot air blower!

Amarok 2011
1.7 Wheel change, installation instructions

for wheel change
agen
AG. Volkswagen AG d
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WARNING ris
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au ra
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Perform ss
the checks
the instructions listed below. and follow
ce
e
This is important to ensure that the wheel bolts and the wheels
nl
pt
du
an
are properly secured.
itte
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ility
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Check to ensure that contact surfaces -arrows- on brake disc
, is n
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are free of corrosion and dirt.
hole
spec
es, in part or in w
t to the co
rrectness of i
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Check to ensure that contact surface -arrow- on centring seat
thi
te
sd
a
of brake disc are free of corrosion and dirt.

iv
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Check to ensure that contact surface -arrow- on inner side of

wheel (rim) and also centring seat of rim are free of corrosion
and dirt.
The concave seats * in the holes for the wheel bolts and the
threads of the wheel bolts must also be free of corrosion and
dirt, oil or grease.
*The concave seat is the curved surface of a section of a sphere
cut by a plane.
1. Wheels, tyres 75
Amarok 2011
Check whether the wheel bolts can be easily screwed in by

hand. The thread of the wheel bolts must not come into contact
with the bore in the brake disc -arrow-.
If the thread of the wheel bolt touches the hole -arrow-, turn the
brake disc relative to the wheel hub accordingly.
If necessary, remove dirt and corrosion, oil or grease from the
contact surfaces, threads in the wheel hub and/or wheel bolts as
necessary.
WARNING
Damaged, badly corroded or difficult to remove wheel bolts

must be renewed.
1.8 Wheel change, wheel installation

Preserving wheel centring seat page 73 .
1- When fitting the wheel, pull in all wheel bolts uniformly by
hand.
olksw
2- Tighten bolts diagonally
swa
and
g evenly.
en AG.V agen AG
does
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3- Lower vehicleseonto
d b the floor and tighten all wheel bolts ara in
nte
diagonal sequence
thori
to specified torque, using torque eo
wrench. s au ra
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s
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WARNING
an
itte
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Do not use an impact screwdriver to screw in the bolts.

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spec
Specified torques
es, in part or in w
t to the co
1.1 Torque settings for wheel bolts, page 71

rrectness of i
l purpos
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mercia
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om
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or
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Prote AG.

Amarok 2011
2 Wheel alignment
2.1 Notes for wheel alignment, page 77
2.2 Necessity of wheel alignment, page 77
2.3 Test prerequisites, page 78
2.4 Test preparations, page 79
2.5 Specified values for wheel alignment, page 79
2.6 Wheel alignment procedure, page 81
2.7 Measuring vehicle longitudinal inclination, page 82
2.8 Adjusting camber and caster at front wheels, page 83
2.9 Adjusting front axle toe, page 83 n AG. Volkswagen AG do
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2.10 Vehicle data sticker, page 84 d b ua
ran
ir se tee
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2.11 Steering angle sender - basic setting,
au page 85
t or
ac
ss
2.1 Notes for wheel alignment
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Wheel alignment must be performed only using a VW/AUDI-ap
rm
ab
proved wheel alignment unit!
pe
ility
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Whenever wheels are aligned, both the front and rear axles must
h re
be measured.
hole
spec
es, in part or in w
Otherwise, the steering rack may not be centred!
t to the co
All the information required to perform alignment can be found in
the wheel alignment computer.
rrectness of i
Current data updates can be found in Volkswagen ServiceNet.
l purpos
VW ServiceNet; Systems; Wheel alignment computer soft

ware; Beissbarth
nform
ercia

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ware; Hunter
a
com
tion in
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ware; Corghi s
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ware; John Bean

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2.2 Necessity of wheel alignment
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The vehicle does not handle properly.
by
cted agen
Prote AG.
Vehicle has been involved in an accident and components
have been renewed.
Axle components have been removed and reinstalled.
Tyres are worn more on one side.
Components have been renewed
Front axle component was renewed. Alignment necessary
Yes No
Lower suspension link X
Wheel bearing housing X
Track rod/track rod ball joint X
Steering rack X
Suspension strut X
Anti-roll bar X
2. Wheel alignment 77
Amarok 2011
Components removed and installed wage

es n
olks ot g
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Front axle component removed
ir se
d and reinstalled
b ua
rAlignment
an necessary
o tee
auth Yes or
ac No
ss
Lower suspension link X
ce
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nl
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Wheel bearing housing X
an
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Track rod/track rod ball joint X
ility
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Steering rack X
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Suspension strut X
hole
spec
Anti-roll bar X
es, in part or in w
t to the co
Note
rrectness of i
Misalignment of steering wheel following removal and installation
l purpos
of components is permitted within a tolerance of 1.5 without

requiring wheel alignment.
nf
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Rear axle
or
thi
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All camber and toe values on the rear axle are prescribed by the
iv
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design. If measured values exceed tolerances, they can only be
o
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corrected/restored by replacing defective/damaged components. en

ng
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2.3 Test prerequisites
t. C rig
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by
Check suspension, wheel bearing, steering and steering link Prote
cted AG.
agen
age for excessive play and damage.
Tread depth difference of no more than 2 mm on one axle.
Tyres inflated to correct pressures.
Vehicle unladen.
Fuel tank must be full.
Spare wheel and vehicle tools are stowed in correct locations.
Windscreen washer fluid reservoir must be full.
When checking wheel alignment, ensure that sliding plates
and turntables are not touching end stop.
Note
To allow running gear to fully settle, wheel alignment should

not be checked before the vehicle has completed 1000 to 2000
km.
When making adjustments, try to adhere to the relevant spec
ifications precisely.
Refer to the user's manual of the equipment maker for proper
attachment and adjustment of the measuring devices.
Wheel alignment platforms and alignment units and comput
ers should be checked and adjusted as necessary during
inspection and maintenance at least once per year!
Handle these highly sensitive measuring devices carefully and
conscientiously.

Amarok 2011
2.4 Test preparations

equipment required
Wheel alignment computer
- V.A.G 1813- or VW/Audi-
approved wheel alignment
units
Brake pedal depressor -
V.A.G 1869/2-
Tool insert - T10179-
Shock absorber set -
T10001-
AG. Volkswagen AG d
agen oes
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The existing lateral run-out of the wheel must be compensated
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for. Otherwise, the result of the measurement will be incorrect.

nf
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If run-out compensation is not performed, it is not possible to ad

or
just toe-in correctly!

m
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Observe information provided by the manufacturer of the wheel

o
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alignment unit.
thi
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Carry out wheel runout compensation.

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Apply brake pedal depressor - V.A.G 1869/2- .

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Use brake pedal depressor to depress brake pedal. t. C rig
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2.5 Specified values for wheel alignment

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Prote AG.
These specifications apply to all engines.
Amarok 2011
The ride heights shown in the table refer to dimension -a-.

Front axle
Front axle Without flared wheel arches With flared wheel arches
Toe-in per wheel (indi +0 5 5 +0 5 5
vidual toe)
Maximum permissible max. 5' max. 5'
difference between
sides n AG. Volkswagen AG do
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Camber (in straight- -0 20 d b30yV
o
-0ua20 30
ot g
ahead position) o
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ran
tee
th or
Maximum permissible max.
au 20' max. 20' ac
difference between ss
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sides
pt
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Caster angle with vehi +4 50 60 +4 50 60
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ility
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Maximum permissible max. 20' max. 20'
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difference between
spec
sides
es, in part or in w
t to the co
Height at a standstill 525 17 mm 518 17 mm
when fuel tank is 90 %
full and a driver's weight
rrectness of i
of 75 kg.
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1) Measuring vehicle longitudinal inclination page 82 .

orm
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Rear axle Without flared wheel arches With flared wheel arches
om
n in
c
Toe-in per wheel (indi +0 0 30 +0 0 30

or
thi
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vidual toe)
t
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Camber (in straight- +0 0 30 +0 0 30

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ahead position)
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Driving axle angle +0 0 20 +0 0 20
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Height at a standstill 585 17 mm 578 17 mm
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when fuel tank is 90 % Prote
cted AG.
agen
full and a driver's weight
of 75 kg.

Amarok 2011
2.6 Wheel alignment procedure

Always adhere to the following procedure!
Comply with instructions in your wheel alignment unit.
Alignment procedure
Start Carry out wheel runout com Bounce springs.

pensation.

Turn steering wheel to Measure vehicle height. Fit brake pedal depressor - V.A.G
straight-ahead position 1869/2-
and lock in place 1)

Check front axle camber Is actual value within toler No
ance?

Yes Adjusting page 83 .

AG. Volkswagen AG d
Check rear axle agen Is actual
kswcamber
oes value within toler No
ol not
ed byV ance?
gu
ara
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ut
ho ee or
a ac
ss Yes Inspect axle components and
ce
le
body
un
pt
an
d
itte

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ab

ility
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is n
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ole,
Check rear axle toe Is actual value within toler No

spec
ance?
t to the co

Yes Inspect axle components and
body
rrectne

s o
cial p

inform
mer
Check front axle caster Is actual value within toler No

atio
ance?
om
n
c

or
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Yes Adjusting caster page 83

iv
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copy Vo
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Prote AG.
Amarok 2011

Check front axle toe Is actual value within toler No
ance?

End Yes Adjust page 83 .

AG. Volks
wagen AG
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1) If steering wheel is not centred, it must be straightened
y V
after gu
edb ara
wheel alignment is finished. Then carry outhobasic
ris setting for steer nte
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ing angle sender - G85- using Vehicle s audiagnostic
t
tester. ra
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2.7 Measuring vehicle longitudinal inclina
erm
ab
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tion
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spec
Protractor - 3021-
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rrectness o
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mer
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Measure vehicle longitudinal inclination at longitudinal mem

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To calculate the caster at zero vehicle inclination, deduct the yri
p by
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measured vehicle inclination value from or add it to the measured
by c lksw
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caster value.
Prote AG.
Example:
Measured vehicle longitudinal inclination Inclined
0 40'
forwards
Specified caster angle for front axle when vehicle + 4 50
longitudinal inclination is 0 60
Specified caster angle taking vehicle longitudinal 4 10
inclination into account 60
Vehicle inclining forwards: subtract measured inclined angle
from specification of 4 50'.
Vehicle inclining rearwards: add measured inclined angle to
specification of 4 50'.
Ensure longitudinal member surface is clean and smooth in
area where measurement is to be taken.

Amarok 2011
2.8 Adjusting camber and caster at front

wheels
Required special tools, test and measuring devices as well as
auxiliary items
Torque wrench - V.A.G 1332/- AG. Volkswagen AG d
agen oes
olksw not
The caster is adjusted on the vehicle using boltd b-1-.
yV gu
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The camber is adjusted on the vehicle usingut
ho bolt -2-. eo
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s a c
s
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spec
t to the co
Remove bolt -1- and replace with a new eccentric bolt Elec
tronic Parts Catalogue ETKA , but do not tighten.
rrectne
Remove bolt -2- and replace with a new eccentric bolt Elec
tronic Parts Catalogue ETKA , but do not tighten.
ss o
Set camber and caster values and then tighten bolts -1- and
cial p
f in
-2- to prescribed torque setting.
form
mer
Specified torques
atio
om
n
c
i
or
n thi
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sion link, page 24

t
sd
iva
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pr
cum
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fo
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ng
t.
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2.9 Adjusting front axle toe
C py
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Required special tools, test and measuring devices as well as
lksw
cted agen
Prote
auxiliary items
AG.
Amarok 2011
Torque wrench - V.A.G 1332/-

Socket - V.A.G 1332/11-
AG. Volkswagen AG d
agen oes
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Loosen lock nut -1- while counterholding on head of track rod
erm
ab
-2-.
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Pull spring-type clip off boot.
h re
hole
spec
Adjust toe by turning left and/or right track rod.
es, in part or in w
t to the co
To to this, it is possible to position an open jaw spanner on hex
agonal profile of track rod.
After turning track rods, ensure that boots are not twisted.
rrectness of i
Twisted boots wear out quickly.
l purpos
nform
ercia
Tighten lock nut -1- with tool insert AF 24 - V.A.G 1332/11- .

m
at
om
i
Counter hold on track rod ball joint -2-.
on
c
in t
or
Check toe values again.
his
ate
do
riv
It is possible that the value will change slightly when lock nut is
p
cum
or
tightened.
f
en
ng
t.
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op
However, if the measured toe value lies within the tolerance, the C py
t. rig
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adjustment is correct.
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pyri by
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Fit spring-type clip to boot. cted agen
Prote AG.
Specified torques
3.3 Repairing steering rack, page 110
2.10 Vehicle data sticker

Explanation of PR numbers on vehicle data sticker
Various types of running gear are installed depending on engine
and equipment level. These are identified by the PR numbers.
The PR numbers are critical in determining the wheel alignment
specifications.
The running gear version fitted in the vehicle is indicated on the
vehicle data sticker by the PR number for the front axle.
The vehicle data sticker can be found in the spare wheel well and
in the service schedule.

Amarok 2011
Example of a vehicle data sticker

In this example, the vehicle is equipped with sports running gear
G28 -arrow-.
2.11 Steering angle sender - basic setting

If steering wheel was realigned, basic setting of steering angle
sender - G85- must be checked Vehicle diagnostic tester!
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
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nl
pt
du
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spec
es, in part or in w
t to the co
rrectness of i
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Prote AG.
Amarok 2011
3 Vibration due to wheels/tyres - cau

ses and rectification
3.1 Causes of vibration, page 86
3.2 Conducting a road test before balancing wheels,
page 86 .
3.3 Balancing wheel, page 87
3.4 Vibration control system, page 91
3.5 Checking radial and lateral runout of wheels and tyres,
page 91
3.6 Checking radial and lateral run-out on wheel rim,
page 92
3.7 Matching wheels and tyres, page 93
3.8 Determining flat spots on tyres, page 94
3.1 Causes of vibration

Vibration can have a number of different causes. Vibration can
also be caused by tyre wear. Tyre wear caused by driving is not
always evenly spread across the entire running surface of the
tyre. This causes slight imbalances which affect the smooth run
ning of a wheel which was previously exactly balanced.
Minor imbalances will not be felt at the steering wheel, but that
does not mean that they are not there. They increase wear on the
tyre and thus reduce the tyre service life.
Recommendation
To ensure
optimal safety,
smoothest possible running and
AG. Volkswagen AG d
even wear agen oes
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throughout a tyre's service
rised
life, we recommend having the wheels nte
and tyres balancedaut at least twice during the tyre's service life. or a
ho e
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3.2 Conducting a road test before balancing
ce
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nl
pt
du
wheels
an
itte
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If a customer brings a vehicle to the workshop complaining about

ility
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vibration, a road test is essential prior to balancing the wheels.

wit
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hole
This will give you information about the nature of the vibration.
spec
es, in part or in w
You will be able to determine the speed range in which vibra

t to the co
tion occurs.
Raise the vehicle on a lifting platform immediately after the
rrectness of i
road test.
l purpos
Mark the positions of the tyres on the vehicle.

Tyre position Marked with
nf
ercia
or
Front left tyre FL

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atio
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Front right tyre FR

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Rear left tyre RL

thi
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Rear right tyre RR

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Remove wheels.
t.
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86
cted agen
Prote
Rep. gr.44 - Wheels, tyres, vehicle geometry
AG.
Amarok 2011
Balance wheels.
3.3 Balancing wheel

Requirements
Before you start balancing the wheels, the following requirements
must be met.
Tyre pressure must be OK.
The tyre tread must not show one-sided wear and should be
at least 4 mm deep.
The tyre must not show any signs of damage, for example
cuts, piercing, foreign bodies, etc.
The wheel suspension, steering and steering linkage, includ
ing the shock absorbers, must
en AG. V
olkbe
swain
genperfect
AG condition.
ag does
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You must haveVol
by conducted a road test. d
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Balancinguwheel,
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balancing wheel on stationary wheel balancer
eo
ra
sa c
Roads test has been carried out page 86 .
ce
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nl
pt
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Clamp wheel into wheel balancing machine
an
itte
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erm
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ility
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Note
wit
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hole
When balancing tyres, please remember that cleanliness is ab spec

solutely essential, as is the case in any other repair work you carry
es, in part or in w
t to the co
out. Only then can you attain a flawless result!
Dirt and rust in the area of the contact surfaces and centre of the
rrectness of i
wheel distort the result.

l purpos
Clean contact surface, centring element and inside of wheel

using e.g. pneumatic brush grinding set - VAS 6446- Volks
wagen ServiceNet; Workshop Equipment, Catalogue before
nform
ercia
clamping wheel on wheel balancing machine!

m
at
om
ion
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in t
or
Note
his
ate
do
priv
It is very important that the correct tools for centring and clamping
um
for
en
g
the wheels are used on the wheel balancing system. Before com
n
t.
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mencing any work, find out about the respective centring system
Cop py
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for wheel balancing machines Volkswagen ServiceNet; Work
t
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shop Equipment, Catalogue . cop Vo
by lksw
cted agen
Prote AG.
3. Vibration due to wheels/tyres - causes and rectification 87

Amarok 2011
Attach the wheel (together with tyre) to the wheel balancing

machine.
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
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un
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pe
ility
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spec
es, in part or in w
t to the co
rrectness of i
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nform
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com
tion in
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s
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Cop py
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Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011
Running ogear,
lksw
axles, steering - Edition 01.2013
AG. V agen AG
agen does
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Note tho
r eo
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c
ss
To clamp the wheel in place, use centring system for wheel
ce
e
nl
pt
balancing machines - VAS 5271- , for example.
du
an
itte
y li
This ensures that the wheel is 100% centred and that the
erm
ab
ility
wheel will be clamped without damage!
ot p
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The wheel cannot be centralised 100% with conical clamping
h re
elements on the wheel balancing machine. hole
spec
es, in part or in w
A deviation of 0.1 mm from the centre results in an imbalance
t to the co
of 10 grams at the wheel/rim.
rrectness of i
Procedure for balancing wheels and tyres
l purpos
Allow the wheel (together with tyre) to rotate on the wheel bal
ancing machine.
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Check that the indicator lines on the sidewalls of the tyre near
the wheel rim flange run evenly.
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Check tyre profile with wheel/tyre rotating.
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this case, the tyre must be renewed.
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Check true running of the wheel/tyre. If the wheel and tyre do
not run true although there are no flat spots, radial or lateral
run-out may be the cause.
Check the wheel for radial or lateral run-out page 91 .
If radial and lateral run-out are within the specified tolerance,
balance the wheel and tyre.
Note
More than 60 grams of weight per tyre should not be used.

If more weight is required, you may be able to achieve smooth
er running by "matching" the tyre and rim. Matching tyres
page 93 .
The wheel balancer display should indicate 0 gram.
As an alternative to match mounting, you could use the vibra
tion control system - VAS 6230 A- page 91 .
Bolt wheel onto vehicle.

First, tighten lowest wheel bolt hand-tight.
Then, tighten all remaining wheel bolts in diagonal sequence.
This process centres the wheel on the hub.
Lower vehicle onto its wheels.
Now use the torque wrench to firmly tighten the wheel bolts
diagonally to the prescribed torque.
Carry out road test
After balancing the wheels and tyres, carry out a road test.

Amarok 2011
If you detect vibration during the road test, it may be due to tol
erance in the wheel centring.
In unfavourable circumstances, the component tolerances of
wheels and hubs could cumulate. This too can lead to vibration.
This vibration can be eliminated by using a finish balancer.
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If you determine a residual imbalance greater than 20 grams
t to the co
when balancing the wheels, you should rotate the mounting po
sition of the wheel on the hub.
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Mark the point at which the imbalance is indicated.
l purpos
Then, unbolt the wheel and rotate its position on the hub so
that the marking points downwards.
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Note
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The hub must not rotate during this procedure.

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First, tighten lowest wheel bolt hand-tight.
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Check whether the imbalance is less than 20 grams using the
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finish balancer.
Note
The imbalance should always be less than 20 grams before you

change the balance weight.
Loosen the wheel bolts again if necessary.

Rotate wheel again by one or two wheel bolt holes in relation
to wheel hub.
Tighten wheels using the method described above.
Note
Do not try to reduce the imbalance using balancing weights until

the imbalance is less than 20 grams.
Balance wheels if imbalance is less five 5 grams.

Tighten wheel bolts to specified torque if you have not already
done so.

Amarok 2011
WARNING
Always tighten wheel bolts to specified tightening torque using

a torque wrench!
3.4 Vibration control system

Using the vibration control system - VAS 6230 A- you can perform
more functions than just stationary balancing.
A special feature of this system is the testing of the radial force of
the wheel and tyre while rolling.
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A roller presses against the wheel with a force of about 635okg. ksw
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The -VAS 6230 A- detects and stores the position of the maximum
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3.5 Checking radial and lateral runout of
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Radial and lateral run-out occur when the wheel and tyre do not
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run absolutely true.
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For technical reasons, 100% true running is not possible.
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Therefore, the manufacturers of these components allow a pre
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The table shows the maximum permissible tolerances for a wheel cted agen
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with mounted tyre.
Tolerances for radial and lateral runout of wheels with tyres
Wheel with tyre Radial run-out (mm) Lateral run-out (mm)
Passenger cars 0,9 1,1
(1.3 in vicinity of lettering)
Checking lateral run-out

Preload tyre gauge approx. 2 mm.

Amarok 2011
Fit tyre gauge to side wall of tyre.
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Turn wheel slowly. db ran
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In this case, you can reduce lateral run-out by match mounting
the tyre page 93 .
Extreme values on the tyre gauge due to small irregularities in the
rrectne
rubber may be disregarded.
s
Checking radial run-out
s o
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Preload tyre gauge approx. 2 mm.
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Fit tyre gauge to running surface of tyre.

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Turn wheel slowly.
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AG.
great.
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tyre page 93 .
3.6 Checking radial and lateral run-out on

wheel rim
Attach the wheel rim to the wheel balancing machine .
Use the centring system for wheel balancing machines - VAS
5271- .
Preload the tyre gauge approx. 2 mm.
Turn wheel rim slowly.
Make a note of the smallest and largest deflection of the indi
cator needle.
S - Lateral run-out
H - Radial run-out
Compare the measured values with the specifications in the
table page 93 .
Note
Extreme values on the tyre gauge due to small irregularities may

be disregarded.

Amarok 2011
Specifications for radial and lateral runout on wheel

Rim Radial run-out (mm) Lateral run-out (mm)
Steel wheel 0,5 0,5
Alloy wheel 0,5 0,8
Note
If the measured value exceeds the specification, acceptably

smooth running cannot be attained.
3.7 Matching wheels and tyres

General
When radial or lateral runout of the wheel and tyre coincide, the
imbalance of the wheel is amplified by the tyre.
For technical reasons, 100% true running is not possible
page 91 . agen
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Before match mounting by the used wheels which are fitted
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Let air out of tyre.

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Press tyre beads off wheel rim flanges.

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Apply tyre assembly paste all round the tyre beads.

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Rotate tyre by 180 relative to wheel rim.

t to the co
Pump up tyre to approx. 4 bar.

Attach the wheel (together with tyre) to the wheel balancing
machine.
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Check wheel for true running and for radial and lateral runout .
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Note
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If the specified values for radial and lateral run-out are not ex
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If the radial and lateral run-out is not within the specifications,

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Let air out and press tyre beads off the wheel rim flanges.
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Rotate tyre by 90 relative to wheel (quarter of a turn).
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Pump up tyre again to 4 bar and check true running.
Note
If the specified values for radial and lateral run-out are not ex
ceeded, the wheel can be balanced to 0 gram.
If the radial and lateral run-out are not within the specified val
ues, the tyre must be rotated again.

Amarok 2011
Press tyre off wheel rim flange again as described above.

Rotate tyre by 180 relative to wheel rim (half a rotation).
If the radial and/or lateral runout are still not within the specified
values, check the wheel for radial and/or lateral runout
page 92 .
If the measured values for radial and lateral runout of the wheel
are within the specified values, the tyre has impermissibly high
radial or lateral runout. In this case, the tyre must be renewed.
Note
After fitting the tyres there will be fitting lubricant between the
tyres and the rim flanges.
You should therefore avoid severe braking and acceleration
manoeuvres for the first 100 or 200 km driven. The tyres may
otherwise rotate on the rims and the work will have been in
vain.
3.8 Determining flat spots on tyres

What is a flat spot?
The terms flat area and flats are also used for the term flat spot.
Flat spots caused by storage or handling also cause vibration in
the same way as incorrectly balanced wheels do. It is important
that flat spots on the tread are identified as such.
Flat spots caused by storage or handling cannot gen AGbe balanced and
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full braking Wheels andssTyres Guide - General Information;
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Rep. gr. 44 ; Rolling noises due to tyres, locked-brake flat spots .
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Note
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Flat spots caused by hard braking cannot be repaired. Such tyres

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must be renewed.
spec
t to the co
Reasons for flat spots caused by storage or handling:

The vehicle has been left standing in one place without being
moved for several weeks.
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The tyre pressure is too low.

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The vehicle was placed in a paint shop drying booth after being
cial p
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painted.
form
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The vehicle was parked with warm tyres in a cool garage or

atio
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similar for a long period of time. In this case, a standing flat

o
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spot may even occur overnight.

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Eliminating flat spots caused by storage or handling

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Flat spots caused by storage or handling cannot be eliminated

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from the tyre using workshop equipment.
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Flat spots caused by storage or handling can be removed only
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by running the tyres warm. by c lksw
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Prote AG.
The method described below is not recommended in cold and
wintry weather.

Amarok 2011
Requirements and conditions:

If necessary, check tyre pressure and correct.
If possible, drive the vehicle onto a motorway.
Traffic and road conditions permitting, drive a 20 to 30 kilo
metre stretch at a speed of 120 to 150 km/h.
WARNING
Do not endanger yourself or other road users during this

road test.
Observe the highway code and speed limitations in force
when performing the road test.
Jack up the vehicle immediately after the trip.

Unbolt wheels from vehicle.
Balancing wheels on stationary wheel balancer page 87 .
AG. Volkswagen AG d
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Amarok 2011
48 Steering
1 Steering wheel
1.1 Assembly overview - steering wheel, page 96
1.2 Removing and installing steering wheel, page 96
1.1 Assembly overview - steering wheel
1 - Steering column
Assembly overview
page 99 .
page 100 .
2 - Steering wheel
Different versions possi
ble. Refer to Electron
ic Parts Catalogue
page 96 .
3 - Bolt agen
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Special tools and workshop equipment required pyri by
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96 Rep. gr.48 - Steering

Amarok 2011
Removing
Remove airbag unit on driver side General body repairs,
interior; Rep. gr. 69 ; Airbag; Removing and installing airbag
unit on driver side .
. Volkswage
Turn steering wheel tokcentre
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Remove bolt -3-.
1. Steering wheel 97
AG. Volkswagen AG d
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Running gear, axles, steering - Edition 01.2013 tho r eo
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Pull steering wheel -2- off steering column.
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Installing
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Put steering wheel -2- onto steering column.
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Centre markings of steering wheel and steering column
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-arrows- must align.
spec
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Prote AG.
Guide connector for steering angle sender - G85- -1- into in

tended opening in the base of steering wheel.
Secure steering wheel with bolt -3-.
Install airbag unit on driver side General body repairs, in
terior; Rep. gr. 69 ; Airbag; Removing and installing airbag
unit on driver side .
Specified torques
1.1 Assembly overview - steering wheel, page 96

AG. Volkswagen AG d
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Running
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2 Steering column
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2.1 Assembly overview - steering column, page 99
ility
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2.2 Removing and installing steering column, page 100
h re
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spec
2.3 Handling and transporting steering column, page 104
es, in part or in w
t to the co
2.4 Checking steering column for damage, page 104
2.1 Assembly overview - steering column
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Note
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It is not permitted to carry out welding and straightening operations on load-bearing or wheel-guiding sus
or
pension components.
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Always renew self-locking nuts.
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Always renew corroded nuts and bolts.

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2 - Steering column
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page 100 .
3 - Bolt
Observe tightening se
quence page 103 .
20 Nm
4 - Bolt
Observe tightening se
quence page 103 .
8 Nm
5 - Nut
5 Nm
2. Steering column 99
Amarok 2011
2.2 Removing and installing steering col

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Torque wrench - V.A.G 1332- olksw
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Removing
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Only the complete steering column is supplied as a replacement
l purpos
part. Repair is not possible.

Steering lock housing can be transferred Electrical system;
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Rep. gr. 96 ; Removing and installing steering lock housing . orm

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WARNING
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The following conditions must be met before starting work on

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the electrical system and removing the steering wheel:

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t.
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Disconnect earth strap from battery Electrical system;
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Rep. gr. 27 ; Battery; Disconnecting and reconnecting the
. C rig
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rig
battery . py by
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Wheels must be in straight-ahead position. Prote AG.
Failure to comply with these precautions may lead to subse

quent failure of the airbag system!
Turn wheels to straight-ahead position.

Raising vehicle .

Amarok 2011
Unscrew bolt -arrow- from universal joint -1- and pull off uni
versal joint in -direction of arrow-.
Remove nuts -arrows- for steering column boot from plenum

chamber bulkhead. agen
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Pull down lever on side of steering column.au
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Swing steering column down as far as possible and pull out.
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Press lever on side of steering column back up.

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Remove airbag General body repairs, interior; Rep. gr. 69 ;
ility
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Airbag; Removing and installing airbag unit on driver side .
wit
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Remove steering wheel page 96 .
spec
Remove steering column switch Electrical system; Rep. gr.
t to the co
94 ; Removing and installing steering column switch .
Removal and installation of the coil connector with slip ring must
rrectne
be carried out with the wheels in the straight-ahead position.
Coil connector with slip ring is secured as a new part in the centre
s
position with a cable tie.
s o
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Vehicles with ESP
form
mer
Vehicles with ESP are additionally equipped with a steering angle
atio
m
sensor - G85- . It is fitted in a housing together with the slip ring

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and coil connector.
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After installation work on steering column switch, basic settings

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for steering angle sender - G85- must be carried out.

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Continuation for all vehicles t. Cop py
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Unplug connector -1- from immobiliser reader coil - D2- .
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Pull connector -2- off steering lock housing.
Unbolt earth cable for steering column.
Remove earth cable and steering column switch line from ca
ble retainer.
Fold floor covering back slightly.

Amarok 2011
Pull boot -1- out of plenum chamber bulkhead.
AG. Volkswagen AG d
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Unscrew lower securing boltth-arrow-
or on left from mounting eo
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Unscrew bolts -arrows- from steering column and hold steer
l purpos
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Lower steering column -2- slightly and carefully pull back
Prote AG.
wards in relation to driving direction out of guide -arrow- on

mounting bracket -1-.
Caution
Take great care to ensure the steering column is handled and

transported correctly page 104 .
Installing

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o ot g
yV Running ran gear, axles, steering - Edition 01.2013
d b ua
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u or
Insert steering
ss
a column -2- with raised areas -arrow A- into ac
guides -arrow B- on mounting bracket -1-.
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wit
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Swivel steering column up, align with mounting bracket and

position.
nform
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Holes -arrows- and journals -1- must align.

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The correct installation position of the steering column relative to
ion in
the mounting bracket is guaranteed only in this way.
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When installing steering column, adhere strictly to bolting se t. C rig
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Tighten steering column bolts -arrows-.

Release lever on side of steering column.
Screw in lower securing bolt -arrow- and tighten.

Install airbag unit General body repairs, interior; Rep. gr.
69 ; Airbag; Removing and installing airbag unit on driver side .
WARNING
When connecting battery ensure that no people are in the ve

hicle!
Vehicles with ESP

Perform basic setting for steering angle sender - G85- using
Vehicle diagnostic tester.
Specified torques
2.1 Assembly overview - steering column, page 99
3.1 Assembly overview - steering rack, page 106

Amarok 2011 AG. Volkswagen AG d
agen oes
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Volksw steering - Edition 01.2013 not
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2.3 Handling and transporting steering col or ac
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WARNING
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ility
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Adherence to proper steering column handling is essen
is n
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tial.
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spec
Improper handling of steering column may damage the
t to the co
steering column, leading to safety risks.
rrectne
Proper steering column handling and transport
Use both hands to transport steering column.
ss o
cial p
f
Hold steering column at upper jacket tube and in area just
inform
above lower universal joint.
mer
atio
Do not touch or contaminate plastic tube on intermediate
om
n
steering shaft.
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
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gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Improper handling of steering column with safety risks

Following methods of handling will damage universal joint bushes
and lower steering column bearing:
Transporting steering column with one hand on jointed shaft.
Bending joints more than 90.
2.4 Checking steering column for damage

Visual check
Check all steering column parts for damage.
Checking function
Check that steering column turns smoothly and easily.

Amarok 2011
Check whether steering column can be moved in the longitu

dinal direction and vertically.
AG. Volkswagen AG d
agen oes
olksw not
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nl
pt
du
an
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011
3 Steering rack
3.2 Removing and installing steering rack, page 107
3.4 Checking shock absorber mountings, page 110
3.5 Removing and installing shock absorber mountings, page
111
3.6 Removing and installing track rod, page 114
3.7 Removing and installing track rod ball joint, page 116
. Volkswage n AG n AG d
wage oes
3.8 Removing and installing boot, page
yV
118
olks not
gu
db ara
ise
3.1 Assembly overviewho - steering rack
r nte
eo
ut a ra
ss c
ce
e
nl
pt
1 - Ladder frame
du
an
itte
y li
2 - Steering column
erm
ab
ility
ot p
3 - Bolt
wit
, is n
h re
hole
spec
moving
es, in part or in w
35 Nm +90
t to the co
4 - Pressure line
Various versions
rrectness of i
l purpos

5 - Union bolt
nform
ercia
32 Nm
m
at
om
6 - Return line
on
c
in t
or
7 - Banjo bolt
his
ate
do
riv
35 Nm
p
cum
for
en
g
8 - Sealing ring
n
t.
yi Co
op py
Always renew after re t. C rig
gh ht
moving yri
p by
co Vo
by lksw
cted
9 - Power steering rack
agen
Prote AG.

page 107 .
10 - Bolt
moving
90 Nm +120
11 - Nut
moving

Amarok 2011
3.2 Removing and installing steering rack

equipment required
Hose clamps, up to 25 mm
- 3094-
Torque wrench -
V.A.G 1332-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
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h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
Removing
rrectness of i
Raising vehicle .
l purpos
Remove wheels.
Remove engine/gearbox guard, if fitted General body re
nf
ercia
pairs, exterior; Rep. gr. 50 .

rm
m
atio
m
Clamp off suction hose and return line using hose clamps to
o
n in
c
25 mm diameter - 3094- .
or
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3. Steering rack 107

Amarok 2011
ly.
Caution
AG. Volkswagen AG d
agen oes
lksw not
Leave nut screwed on a few turns to protect thread on pin. d by Vo gu
ara
rise nte
tho eo
au ra
s c
Push track rod off wheel bearing housing and remove
s nut.
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
Unscrew bolt -arrow- from universal joint -1- and pull off uni
h re
hole
versal joint in -direction of arrow-.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
Unscrew pressure line -1- from steering rack and pull it out.
s
iva
do
r
rp
c
Close off line with a plastic bag and adhesive tape.
um
fo
en
ng
t.
yi
Remove banjo bolt -2- for return line from steering rack.
Co
Cop py
t. rig
Close off line with a plastic bag and adhesive tape.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Remove bolts -arrows- for steering rack -1- from ladder frame.
Note
Bolt on left side of vehicle is screwed into a nut.
Remove steering rack to left side of vehicle.
Note
Watch out for narrow point at front final drive!

Do not damage control line on steering rack!
Installing

Amarok 2011
Note installation position of pressure line.

Pressure line -1- must be installed at a distance -a- of at least
2 mm from steering rack -2-.
Mounting stop -arrow- of return line -3- must be in contact with
steering rack when tightened.
Note
Use new seals.
Bleed steering system page 127 .

Check steering system for leaks page 128 .
Check hydraulic fluid level and top up if necessary
page 127 .
Check wheel alignment after completing the installation
page 77 .
AG. Volkswagen AG d
Specified torques lksw
agen oes
not
Vo gu
by
3.1 Assembly overview
ised - steering rack, page 106 ara
nte
or eo
h
aut ra
s c
s Component Specified torque
ce
e
nl
pt
du
Track rod to wheel bearing housing an 90 Nm

itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
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f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Amarok 2011
3.3 Repairing steering rack
1 - Track rod ball joint

Right.
Identified with an ar
row pointing in direction
of travel
Check that dust caps
are undamaged and
correctly seated.
Tapered pin must be
a dry cloth but do not
use cleaning solutions.
2 - Hexagon nut
90 Nm
3 - Spring-type clip
4 - Boot
Check for damage
Do not twist when ad
justing track.
5 - Clamp
moving
6 - Track rod
100 Nm
page 114 .
7 - Shock absorber mounting
AG. Volkswagen AG d
Check upper and lower agen oes
olksw not
V
collars for damage in d by gu
ara
pressed-in condition rise nte
tho eo
u ra
Use assembly lubricant ss a c
for installing Electronic Parts Catalogue (ETKA) .
ce
le
un
pt
Check shock absorber mountings for wear page 110 .

an
d
itte
y li
rm
ab
8 - Power steering rack

pe
ility
ot

wit
, is n
h re
9 - Sealing ring
hole
spec
es, in part or in w
10 - Track rod ball joint

t to the co
Left.
Identified with an arrow pointing in direction of travel
rrectness of i
Check that dust caps are undamaged and correctly seated.

l purpos
Tapered pin must be free of oil and grease.

nform
mercia
a
com
tio
3.4 Checking shock absorber mountings

n in
r
te o
thi
High mileage and environmental influences (dust, sand, mud, bad

s
iva
do
r
roads) can cause wear to the shock absorber mountings of the

rp
cum
fo
steering rack. As wear progresses, material may be scoured away

en
ng
t.
yi
and/or the rubber collar of the shock absorber mountings may
Co
op py
deteriorate, so that in extreme cases this collar may disappear t. C rig
gh ht
yri by
110
cop Vo
by lksw
Rep. gr.48 - Steering Prote
cted AG.
agen
Amarok 2011
completely and the base of the steering rack may, in the lower
position, completely contact the steering rack connection.
The threaded connection of the steering rack is not affected by
wear to the bush and is OK.
Using commercially available 0.5 mm feeler gauge, check gap
between base of steering rack and steel support.
If the rubber collar of the shock absorber mounting -arrow- can
be felt, then it is not necessary to renew the shock absorber
mounting.
lkswage es n
o ot g
byV ua
If the gap -arrow- is smaller than the rfeeler
ise
d gauge, then both shock ran
tee
absorber mountings should be renewed.utho
or
a ac
ss
Removing and installing shock absorber mountings
ce
le
un
page 111 .
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
3.5 Removing and installing shock absorber
l purpos
mountings
nform

mercia

a
com
tion in
r
te o
thi
s
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rp
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ng
t.
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Cop py
t. rig
gh ht
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Vo
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cted agen
Prote AG.

Amarok 2011
Thrust piece - VW 454-
AG. Volkswagen AG d
agen oes
olksw not
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ara
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ris nte
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aut ra
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ce
le
un
pt
Removing
an
d
itte
y li
Undo bolt of rear bush of bevel gear.
erm
ab
ility
ot p
Remove bolts -arrows- for steering rack -1- from ladder frame.
wit
is n
h re
ole,
spec
Note
t to the co
Bolt on left side of vehicle is screwed into a nut.
rrectne
Unscrew bolt -arrow- from universal joint.
s
Pull off steering rod in -direction of arrow-.
s o
cial p
f
Pull steering rack forwards until the damping bushes are easily
inform
accessible.
mer
atio
m
Combine assembly tool - 3301- and assembly tool - 3346- with

o
n
c
thrust piece - VW 454- as shown in the illustration.

i
or
n thi
te
sd
iva
o
pr
cum
r
Note
fo
en
ng
t.
yi Co
op py
Use a standard nut with a washer instead of the nut of the as
. C rig
ht ht
sembly tool.
rig by
copy Vo
by lksw
cted agen
Prote AG.
Tighten standard nut with washer.
Pull out shock absorber mounting by pulling threaded rod
-3301M- downwards.

Amarok 2011
If necessary, counterhold standard nut with spanner.

Installing
Use assembly lubricant for installing Electronic Parts Cata
logue (ETKA) . . Volkswagen AG
gen AGa d oes
ksw not
y Vol gu
b ara
WARNING ris
ed nte
tho eo
au ra
If you use assembly lubricant
ss Electronic Parts
Catalogue c
ce
le
(ETKA) , the vehicle must not be moved for several hours as

un
pt
otherwise the shock absorber mountings may become twisted.
an
d
itte
y li
The assembly lubricant Electronic Parts Catalogue (ETKA)
rm
ab
must first evaporate.
pe
ility
ot
wit
, is n
h re
hole
Press shock absorber mounting into bush.
spec
es, in part or in w
t to the co
Note
rrectness of i
The markings on the shock absorber mountings -arrows- must be
aligned to the direction of travel.
l purpos
nform
ercia
Pull in shock absorber mounting by pulling threaded rod

m
a
com
t
-3301M- upwards.
ion in
r
te o
thi
If necessary, counterhold nut -3301- with spanner.
s
iva
do
r
rp
cum
fo
en
ng
t.
yi
Note
Co
Cop py
t. rig
gh ht
yri
Press in shock absorber mounting 5 mm further than dimension
p by
co Vo
by lksw
specified. Then push it back 5 mm until the rubber lips are uni Prote
cted AG.
agen
formly seated on both sides.
Fasten steering rack to conductor frame.

Bolt bevel gear onto rear bush.
Note
Misalignment of steering wheel following removal and installation

of components is permitted within a tolerance of 1.52) without
requiring wheel alignment.
2) If the tolerance is greater than the permissible value, wheel alignment must be
carried out. page 77
Specified torques
Rear bush of bevel gear 60 Nm + 90

Amarok 2011
3.6 Removing and installing track rod

equipment required
Torque wrench -
V.A.G 1332-
Open-end spanner attach
ment - V.A.G 1923-
Locking pliers - VAS 6199-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing
nform
ercia

Raising vehicle .
m
at
om
ion
c
Remove wheel.
in t
or
his
ate
do
riv
ly.
p
cum
for
en
ng
t.
yi Co
op
Caution
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Clean outside of power steering rack in vicinity of boot.

Amarok 2011
Open clamps -arrows- and push boot back.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
Use open-end socket attachment - V.A.G 1923- to unscrew
t to the co
track rod.
Installing
rrectne
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
Make sure that correct track rod ball joint is installed on each
en
ng
t.
yi
side.
Co
Cop py
ht. rig
ht
Arrow on track rod ball joint must always point in direction of trav
rig by
opy Vo
el. by c lksw
cted agen
Prote AG.
I - Left track rod ball joint
II - Right track rod ball joint

Amarok 2011
Tighten track rod using open-end spanner attachment - V.A.G

1923- .
Check boots for wear (splits, tears) and check sealing surfaces
for soiling.
Install boot and clamp.
Note
Only use genuine clamps.

Check wheel alignment after completing the installation
page 77 .
Specified torques . Volkswagen AG
gen AG does
swa
3.3 Repairing steering rack, y V page 110
olk not
gu
edb ara
ris nte
ho eo
aut
Component r a Specified torque
ss c
Track rod to wheel bearing housing 90 Nm
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
3.7 Removing and installing track rod ball
wit
is n
h re
joint
ole,
spec

Ball joint puller - T10187- t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing
Raising vehicle .
Remove wheel.

Amarok 2011
ly.
Caution
AG. Volkswagen AG d
agen oes
Loosen nut -1-. Vo lksw not
gu
by ara
d
Mark position of track rod ballorisjoint
e
on track rod. nte
eo
th
au ra
Unscrew track rod ball joint
ss -2- from track rod. c
ce
e
nl
Installing
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Make sure that correct track rod ball joint is installed on each
rrectness of i
side.
l purpos
Arrow on track rod ball joint must always point in direction of trav
el.
nform
ercia
I - Left track rod ball joint

m
II - Right track rod ball joint at

om
ion
c
in t
Screw track rod ball joint onto track rod as far as previously
or
his
e
applied mark and secure with lock nut.

at
do
priv
cum
Bolt track rod ball joint with new nut.

for
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
Check wheel alignment after completing the installation yri
p by
o Vo
page 77 .
c by lksw
cted agen
Prote AG.
Specified torques

Track rod ball joint to wheel bearing housing 90 Nm

Amarok 2011
3.8 Removing and installing boot
Note
If boot is defective, moisture and dirt will enter steering rack.

There must be a palpable film of grease in the area of the teeth
on the steering rack. If there is no film of grease, the steering
rack must be renewed.
Also renew steering rack if there is corrosion, damage, wear
or signs of contamination on the steering rack.
Removing
Raising vehicle .
Turn steering wheel to straight-ahead position.
AG. Volkswagen AG d
Remove wheel. lksw
agen oes
not
Vo gu
by
Clean outside riseof steering rack in vicinity of boot.
d ara
nte
tho eo
No dirt musts abe allowed to enter the steering rack through a de
u ra
c
fective rubber boot during this operation.
s
ce
e
nl
pt
du
Remove track rod ball joint page 116 .

an
itte
y li
erm
ab
Open hose clips -arrows-.

ility
ot p
wit
Pull boot off steering rack housing and track rod.

, is n
h re
hole
Installing
spec
es, in part or in w

t to the co
Before installation, steering rack must be coated with steering

rack grease provided in repair set Electronic Parts Catalogue
rrectness of i
(ETKA) .
l purpos
Caution
nf
ercia
Never use any other grease.

rm
m
atio
om
n in
or c
thi
To grease, turn steering to full lock on each side in succession.

te
sd
iva
o
r
rp
cu
Grease steering rack on toothed side using steering rack

o
m
f
en
ng
grease Electronic Parts Catalogue (ETKA) .

t.
yi Co
Cop py
t. rig
Turn steering wheel to straight-ahead position. opyri
gh by
Vo
ht
c by lksw
cted agen
Prote AG.

Amarok 2011
Push boot onto track rod and steering rack

AG. Volkand
swagsecure
en AG with
new clamps -arrows-. agen does
olksw not
V y gu
db ara
Install track rod ball joint
or
ise page 116 . nte
th eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011
4 Hydraulic power steering

4.1 Assembly overview - vane pump, page 120
4.2 Assembly overview - hydraulic lines, reservoir,
page 121
4.3 Checking delivery pressure of vane pump, page 121
4.4 Removing and installing vane pump, page 124
4.5 Checking power steering fluid level, page 127
4.6 Bleeding steering system, page 127
4.7 Check steering for leaks, page 128
4.1 Assembly overview - vane pump
1 - Spring retainer
2 - Bush
Drive bush back slightly
when installing vane
pump.
3 - Bolt
24 Nm
4 - Bolt
9 Nm
5 - Pressure line n AG. Volkswagen AG do
lkswage es n
o ot g
Note byV ua
d ran
ir se tee
tho
or
When installing, press on to stop in ss
au ac
vane pump. ce
le
un
pt
an
d
Contains
itte
y li
erm
Item 8 (page 120)

ab
ility
ot p
6 - Suction hose
wit
is n
h re
Note installation posi

ole,
spec
tion on vane pump:

marking -arrow A- must

t to the co
align with marking

-arrow B- on vane
pump.
rrectne
7 - Clamp
s
Install on marking on
s o
suction hose.
cial p
f inform
8 - Sealing ring
mer
atio

om
moving
c
i
or
n thi
te
sd
9 - Vane pump
iva
o
pr
um
r
fo
en
ng

t.
yi Co
op
Fill with hydraulic fluid before installing.
C py
t. rig
gh ht
yri
p by
co Vo
by lksw
cted agen
10 - Belt pulley
Prote AG.
11 - Bolt
23 Nm

Amarok 2011
12 - Bolt
24 Nm
4.2 Assembly overview - hydraulic lines, reservoir
1 - Reservoir
2 - Sealing cover with dipstick
Check power steering
fluid level page 127 .
3 - Spring retainer
For reservoir
4 - Clamp
5 - Return hose
6 - Suction hose
7 - Clamp
8 - Bolt
9 Nm
9 - Spring retainer AG. Volkswagen AG d
agen oes
For engine control unit olksw not
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pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tio
4.3 Checking delivery pressure of vane

n in
r
te o
thi
pump
s
iva
do
r
rp
cum

fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4. Hydraulic power steering 121

Amarok 2011
Hose clamps, up to 25 mm - 3094-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
u ra
Power steering tester - V.A.G 1402- ss a c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness
Adapter set - V.A.G 1402/6-
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Adapter - V.A.G 1402/18-

Clamp off suction hose at vane pump with hose clamp to
25 mm - 3094- .
Remove pressure line from vane pump.

Amarok 2011
Fit special tools as shown in illustration.

1- Vane pump
2- Adapter - V.A.G 1402/18-1- 3)
3- Securing bolt of pressure line Item 4 (page 120)

4- Hose from adapter set - V.A.G 1402/6-
5- Power steering tester - V.A.G 1402-
6- Pressure line
7- Adapter - V.A.G 1402/18-2-
3) If seal is leaking or damaged on adapter - V.A.G 1402/18-1- , replace with new
seal Item 8 (page 120) Electronic Parts Catalogue .
Remove hose clamp, up to 25 mm - 3094- from suction

hose.
Make sure lever on power steering tester - V.A.G 1402- is in po

sition -2-.
Top up hydraulic fluid in reservoir if necessary page 127 .
Start engine.
Turn steering wheel approx. 10 times from lock to lock.
Check delivery pressure
. Volkswagen AG
gen AG does
Test prerequisites:
Vol
ksw
a
not
by gu
d ara
System oris must be free of leaks
e nte
h eo
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Hoses
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With engine idling, turn shut-off valve to position -1- (not longer
than 5 seconds) and read pressure from power steering tester
- V.A.G 1402- .
rrectness of i
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Note
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Ensure that the shut-off valve is not closed in position -1- for more
than 5 seconds to avoid damage to the vane pump.
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Specification for delivery pressure:

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If specification is not attained, renew vane pump page 124 .

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Remove pressure gauge and adapter.
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Bleed steering system page 127 .
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Check hydraulic fluid level and top up with hydraulic fluid if
necessary page 127 .

Amarok 2011
4.4 Removing and installing vane pump

equipment required
Hose clamps, up to 25 mm
- 3094-
Torque wrench - V.A.G agen
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Removing
WARNING
Please note the following points during all assembly work, in

particular in the engine compartment, due to the narrow instal
lation conditions:
Route lines of all kinds (for example for fuel, hydraulic fluid,
activated charcoal filter system, coolant, refrigerant, brake
fluid, vacuum) and electrical cables so that the original
line/cable routing is re-established.
Make sure there is adequate clearance from all moving or
hot components.
If fitted, remove air intake hose.

Remove poly V-belt Power unit; Rep. gr. 13 ; Cylinder head,
pulley end; Removing and installing poly V-belt .

Amarok 2011
Unscrew bolts -arrows-, counterhold poly V-belt pulley -1- with

pin wrench - 3212- for this.
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Clamp off suction hose using hose clamps, up to 25 mm -
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Open spring-type clip -1- and pull suction hose off vane pump.
hole
spec
Close off suction hose with a plastic bag and adhesive tape.
es, in part or in w
t to the co
Remove bolts -2- and pull pressure line out of vane pump.
Close off pressure line with a plastic bag and adhesive tape.
rrectness of i
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Amarok 2011
Remove bolt -arrow- and remove vane pump from retainer.

There is no provision for repairing the vane pump. If problems are
reported, determine the cause by means of a pressure test and a
leakage test page 121 . If a fault is found, the vane pump unit
must be renewed.
Note
Always check steering system for leaks if fluid level in reservoir

is low. AG. Volkswagen AG d
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If leakage appears near pipe connections, first check lines and d by Vo gu
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connections for leaks, tighten connections as necessary and orise nte
wipe dry. aut
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Vane pumps taken from parts stock contain no fluid. Therefore
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it is essential to fill vane pump with hydraulic fluid Electronic
du
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Parts Catalogue (ETKA) and to rotate pump by hand prior to itte
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installation. Otherwise vane pump may be damaged or be
ility
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noisy during operation.
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Fluid type: hydraulic fluid Electronic Parts Catalogue (ET
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es, in part or in w
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Installing
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Fill vane pump with hydraulic oil.
l purpos
Fill hydraulic oil in through connection port of vane pump.
nf
ercia
Turn hub by hand until oil emerges from pressure side.
orm
m
Install vane pump, initially tightening only front bolts.
atio
om
n in
or c
Install suction hose -1- so that marks -arrow A- and
thi
te
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a
-arrow B- aline with one another.

iv
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Mount clamp -2- on mark -arrow A-.
f
en
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Install poly V-belt Power unit; Rep. gr. 13 ; Cylinder head, C py
t. rig
pulley end; Removing and installing poly V-belt .
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pyri by
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Bleed steering system page 127 . cted agen
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Check hydraulic fluid level page 127 .

Specified torques
4.1 Assembly overview - vane pump, page 120

Amarok 2011
4.5 Checking power steering fluid level

When fluid is cold: (approx. 20C):
Unscrew filler cap.
Wipe dipstick with a clean, lint-free cloth.
Screw filler cap on hand tight and unscrew again.
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The cap must be fully hor screwed on in order to obtain an accurate eo
ut
fluid level reading.
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Check fluid level: fluid level should be in area -A-.
an
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t to the co
When fluid is at operating temperature (approx. 80 ):
rrectne
Unscrew filler cap.
Wipe dipstick with a clean, lint-free cloth.
ss o
Screw filler cap on hand tight and unscrew again.
cial p
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mer
atio
m
Note
o
n
c
i
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The cap must be fully screwed on in order to obtain an accurate

t
sd
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fluid level reading.

i
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Check fluid level: fluid level should be in area -B-.
Co
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Note cted agen
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If fluid level is above specified area, excess fluid must be ex

tracted.
If fluid is below specified range, hydraulic system must be
checked for leaks. It is not sufficient just to top up with fluid.
Do not re-use hydraulic fluid which has been drained off.
4.6 Bleeding steering system

Check hydraulic fluid level and top up if necessary.
Raise vehicle until front wheels are free.
Start engine and let it idle.
page 127 .
Turn steering wheel 10 times from lock to lock.
page 127 .

Amarok 2011
Note
Bleeding has finished when no more air bubbles can be seen in

fluid in reservoir.
Lower vehicle.
4.7 Check steering for leaks
Note
If hydraulic fluid level in reservoir is low after repairs are comple

ted, steering system must be checked for leaks.
Start engine and let it idle.

Turn steering wheel left and right to lock and hold briefly.
This develops the maximum possible pressure.
In this position, the following components must be checked for
leaks:
Steering rack: steering pinion on valve block, connection point
between valve and steering rack housing, housing
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Vane pump: shaft seal, all threaded connections, housing ised b ara
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Running Gear, Axles, Steering AMAROK

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Running Gear, Axles, Steering AMAROK

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Service

Service Department. Technical Information

All rights reserved.

Copyright 2013 Volkswagen AG, Wolfsburg D4B80275F7F

4.3 Removing and installing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4.4 Removing and installing upper links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.5 Renewing bushes for upper suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4.6 Repairing front suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4.7 Removing and installing suspension strut mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

5 Lower suspension link, swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

5.1 Removing and installing lower suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

6.1 Assembly overview - drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

6.3 Dismantling and assembling drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

6.4 Checking outer constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

1.1 Overview - rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

1.9 Removing and installing rear axle shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

44 - Wheels, tyres, vehicle geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

2.6 Wheel alignment procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

2.7 Measuring vehicle longitudinal inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

2.10 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

2.11 Steering angle sender - basic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

3 Vibration due to wheels/tyres - causes and rectification . . . . . . . . . . . . . . . . . . . . . . . . . . 86

3.1 Causes of vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

3.3 Balancing wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

3.4 Vibration control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

3.7 Matching wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

3.8 Determining flat spots on tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

1.1 Assembly overview - steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

1.1 Checklist for evaluating running gear on

Check steering rack and lines for secure seating.

Check for flawless function from lock to lock by moving the

steering from stop to stop. In the process, the steering wheel

must turn with a constant force without resistance.

Visual inspection and functional check of running gear

Adhere to the sequence of the following inspection steps!

deformation, cracks and other damage.

Align wheels on a Volkswagen AG-approved wheel alignment

Visual and functional check of wheels and tyres

Check for true running and imbalance page 86 .

plies if the circumstances of the accident and the damage to the

1. Evaluating accident vehicles 1

If in doubt, the following applies:

2 Rep. gr.00 - Technical data

2.1 Tyre types

3.1 Steering rack

which were otherwise repeated in the relevant sections of the

system, see Self-study programme No. 399 ; Electromechan

For a description of the design and function of the electrome

sleeves between bracket and steering rack are seated cor

Place removed parts on a clean surface and cover them to

this purpose. Use only lint-free cloths.

3.2 Gaskets and seals

4 Rep. gr.00 - Technical data

3.3 Nuts and bolts

Specified torques given are for unlubricated nuts, bolts and

Always renew self-locking nuts and bolts.

accumulated by the human body. This charge can cause mal

Before working on electrical components, touch an earthed

Engine and gearbox jack -

Tensioning strap - T10038-

6 Rep. gr.00 - Technical data

bushes may be tightened only when the component is in the

unladen position (normal position) or the vehicle is standing on

its wheels and is unladen.